WO2025030368A1

WO2025030368A1 - Method to manufacture non-linear coupled integrated inductor

Info

Publication number: WO2025030368A1
Application number: PCT/CN2023/111736
Authority: WO
Inventors: Xiaobing Zhou; Xiaoguo Liang; Yitai CHAO; Alan Wu; Kaladhar Radhakrishnan; Jonathan Douglas
Original assignee: Intel Corp
Current assignee: Intel Corp
Priority date: 2023-08-08
Filing date: 2023-08-08
Publication date: 2025-02-13
Anticipated expiration: 2026-02-08

Abstract

Embodiments disclosed herein include an inductor. In an embodiment, the inductor comprises a first core and a second core. In an embodiment, a third core is between the first core and the second core. A first gap is provided between the first core and the third core and a second gap is provided between the second core and the third core. In an embodiment, the third core comprises, a first portion with a first width, a second portion with a second width, and a third portion with a third width between the first portion and the second portion. In an embodiment, the third width is smaller than both of the first width and the second width.

Description

METHOD TO MANUFACTURE NON-LINEAR COUPLED INTEGRATED INDUCTOR

TECHNICAL FIELD

Embodiments of the present disclosure relate to electronic systems, and more particularly, to voltage regulators with non-linear coupled integrated inductors.

BACKGROUND

Voltage regulation continues to be an area of interest in circuit design, especially for purposes of preventing unnecessary consumption of power. While all systems can benefit from improvements in voltage regulation, battery-powered devices are particularly amenable to voltage regulation improvements. Promoting efficient management of battery power usage will translate into improved performance, giving users enhanced capability.

In one approach to voltage regulation improvement, inductors that can be operated in a coupled or decoupled state have been proposed. Depending on the current applied to the inductor, either two inductors can be operated independently of each other, or the two inductors can be operated in a coupled configuration. This allows for higher light load efficiency while still providing a fast transient to foster high density power delivery. Ideally, a two-step transition of inductance is used. For example, a high inductance in a decoupled state is used for light loads, or a lower inductance in a coupled state is used for heavy loads. The transition between the two states should be a sharp transition. However, due to existing manufacturing limitations, such a transition is not as ideal as expected. In practice, the transition between the two states is a shallow slope. As such, the transient is not as sharp as possible and efficiency at light load is reduced and transient performance is also impacted.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1A is a cross-sectional illustration of an inductor with an “EI” configuration with a small magnetic bump between the magnetic portions.

Figure 1B is a cross-sectional illustration of the inductor in a decoupled state.

Figure 1C is an equivalent circuit of the inductor in a decoupled state.

Figure 1D is a cross-sectional illustration of the inductor in a coupled state.

Figure 1E is an equivalent circuit of the inductor in a coupled state.

Figure 2A is a cross-sectional illustration of an inductor with an “EI” configuration that includes a gap between the magnetic bump and one of the magnetic portions.

Figure 2B is a graph of the ideal behavior of a two-step inductor and the exhibited behavior of a two-step inductor similar to the one shown in Figure 2A.

Figure 3 is a cross-sectional illustration of an inductor that is formed with three magnetic cores, wherein the central magnetic core is a monolithic structure with a magnetic bridge between end portions, in accordance with an embodiment.

Figure 4A is a cross-sectional illustration of an inductor with three magnetic cores in a decoupled state, in accordance with an embodiment.

Figure 4B is a cross-sectional illustration of an inductor with three magnetic cores in a coupled state, in accordance with an embodiment.

Figure 4C is a graph of the inductance behavior of an inductor similar to the one shown in Figure 3 compared to the inductance behavior of an inductor similar to the one shown in Figure 2A, in accordance with an embodiment.

Figure 5A is a cross-sectional illustration of the central magnetic core with a magnetic bridge, in accordance with an embodiment.

Figure 5B is a cross-sectional illustration of the central magnetic core with a pair of magnetic bridges, in accordance with an embodiment.

Figure 5C is a cross-sectional illustration of the central magnetic core with a magnetic bridge that has a length equal to a length of the end portions, in accordance with an embodiment.

Figure 6 is a cross-sectional illustration of an unstable inductor that provides only decoupled functionality.

Figure 7A is a cross-sectional illustration of an inductor that is mechanically balanced with a rectangular shaped central core, in accordance with an embodiment.

Figure 7B is a cross-sectional illustration of an inductor that is mechanically balanced with an I-shaped central core, in accordance with an embodiment.

Figure 8 is a diagram of a circuit for generating voltage using a voltage regulator that incorporates the inductor for powering different platforms of a terminal, in accordance with an embodiment.

Figure 9 is a cross-sectional illustration of an electronic system that includes one or more voltage regulators with inductors disclosed herein, in accordance with an embodiment.

Figure 10 is a schematic of a computing device built in accordance with an embodiment.

EMBODIMENTS OF THE PRESENT DISCLOSURE

Described herein are electronic systems, and more particularly, voltage regulators with non-linear coupled integrated inductors, in accordance with various embodiments. In the following description, various aspects of the illustrative implementations will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative implementations. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative implementations.

Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention, however, the order of description should not be construed to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.

As noted above, voltage regulator devices have been moving towards the use of inductors that can switch between a coupled state and a decoupled state. Ideally, the switch between states is a sharp step in order to provide the most advantageous efficiency. However, existing solutions fall short, and the transition is typically a shallow slope instead of a step. As such, the efficiency provided by such solutions is not as high as it theoretically could be.

Existing solutions include the use of a so-called EI configuration. In such an instance, a first core is an E shape, and the second core is an I shape. As used herein, a “core” may refer to a body of material used in an inductor. In some instances a “core” may specifically refer to a body of material that comprises a magnetic composition. The outer arms of the E core are purposely spaced away from the I core, and the central arm of the E core is connected to the I core by a magnetic bridge. In a decoupled state, the magnetic bridge is unsaturated (magnetically) . In a coupled state, the magnetic bridge is saturated. Primarily, the sloping transition is provided since a gap will exist between the magnetic bridge and one of the cores due to manufacturing tolerances.

Accordingly, embodiments disclosed herein replace the EI configuration with a three core configuration. In such an embodiment, the central core may have an integrated bridge between a pair of end regions. That is, the bridge and the end regions may be formed from a single monolithic piece. The bridge may have a width that is smaller than a width of the end regions. More particularly, the bridge may have dimensions that allow for magnetic saturation to occur in order to switch the inductor between a decoupled state and a coupled state. Since the central core is monolithic, there is no gap between the end regions and the bridge. Accordingly, behavior that is closer to the ideal state is provided.

To provide context an example of an inductor 100 with an EI configuration is shown in Figure 1A. The inductor 100 may include a first core 110, a second core 120, and a bridge 130 between the first core 110 and the second core 120. The first core 110 may have an E-shape. That is, the first core 110 may have a main body 111 and a set of three protrusions 112, 113, and 114 that extend away from the main body 111 towards the second core 120. The second core 120 may include a body 121. The first core 110 and the second core 120 may comprise magnetic material, such as a ferrite or the like.

In some instances, the bridge 130 is provided between the middle protrusion 113 and the second core 120. The bridge 130 may also be a magnetic material. As shown, the width of the bridge 130 may be smaller than a width of the middle protrusion 113. Accordingly, the bridge 130 may be transitioned between a saturated state and an unsaturated state. As used herein, “saturated” refers to magnetic saturation unless explicitly stated otherwise. The first protrusion 112 may be spaced away from the second core 120 by a first gap G₁, and the third protrusion 114 may be spaced away from the second core 120 by a second gap G₂.

The inductor 100 may also comprise electrically conductive windings 115 and 116. Electrically conductive winding 115 may wrap around the first protrusion 112, and electrically conductive winding 116 may wrap around the third protrusion 114. In a magnetic circuit, magnetic flux will follow the path of least magnetic reluctance. The saturation level of the bridge 130 serves to control the path of travel of the magnetic flux. More specifically, in the inductor 100, changes in the saturation level of the bridge 130 changes the magnetic reluctance paths generated from the winding 115 and 116. This causes the inductor to switch between coupled and decoupled states.

Referring now to Figure 1B, an example of the inductor 100 operating in a decoupled state is shown. As shown, windings 115 around the first protrusion 112 operate as a first inductor, and the windings 116 around the third protrusion 114 operate as a second inductor. Because the first and second inductors operate separately, the inductor 100 is considered to be in a decoupled state.

This decoupled state occurs automatically based on a size of the load current flowing through the inductor in relation to a magnetic permeability of the bridge 130. In the illustrated example, when the load current is less than a predetermined threshold value, the bridge 130 is in a magnetically unsaturated state. As a result, the magnetic flux 131 from the first inductor flows along a low magnetic reluctance path that passes through the middle protrusion 113 and the bridge 130. Similarly, magnetic flux 132 from the second inductor passes through the middle protrusion 113 and the bridge 130.

Also, the magnetic flux 131 and 132 may flow in opposite directions. This may be accomplished by sending current through the windings in different directions. For example, current may be sent into the winding 115 from the side and exit from the top, and current may be sent into the winding 116 from the top and exit from the side.

Referring now to Figure 1C, an equivalent diagram of the inductor corresponding to the decoupled state shown in Figure 1B is shown. In this diagram, because of the low inductance paths through the bridge 130, the first and second inductors L₁ and L₂ operate separately based on currents i₁ and i₂ respectively flowing through their windings. In some instances the sum of currents i₁ and i₂ may be considered to correspond to the load current I₁.

Also, in Figure 1C, switches SW1 and SW2 may be included for selectively switching the inductors L₁ and L₂ to a circuit including the load to be driven. The switches SW1 and SW2 may be alternately closed to couple the same or different inductances of the inductors to a load, illustratively shown by capacitor 135, or only either of the switches SW1 and SW2 may be closed, or both switches SW1 and SW2 may be simultaneously closed, depending on the requirements of the load.

Referring now to Figure 1D, an illustrations of magnetic flux generated when the inductor 100 is operating in a coupled state is shown. In this state, the windings around protrusion 112 and the windings around protrusion 114 produce magnetic flux 137 and 138 which is added together to form the flux (and thus the inductance) of a coupled inductor. If the flux 137 and 138 from the windings flows in the same direction, the net flux (and thus inductance) in the coupled state will be greater than the individual inductances of the windings. Conversely, if the flux 137 and 138 from the windings flows in different directions (as shown in Figure 1D) , some of the flux 137 from one winding will cancel the flux 138 from the other winding. This may produce a net flux (and inductance) in the coupled state that is less than one or both of the windings taken individually.

This coupled state occurs automatically based on a size of the load current in relation to the magnetic permeability of the bridge 130. In this example, when the load current is greater than the predetermined threshold value, the bridge 130 is magnetically saturated. As a result, the bridge 130 functions essentially as a non-magnetic material (e.g., one that is not magnetically permeable such as air) and one part of the magnetic flux 137 and 138 will flow through the second protrusion 113, but a substantial amount of the flux will not flow through the bridge 130; the other part of the magnetic flux 137 and 138 will flow through the side leg protrusion 112, 114.

In operation, the current may be switched into both or only one of the windings. If the current is only switched into one of the windings, the direction of flow of the magnetic flux of the inductor in the coupled state is determined by the inductor winding that receives the input current. For example, if the winding around protrusion 112 receives the input load current, then the magnetic flux of the inductor 100 in the coupled state traverses a clockwise path. If the winding around protrusion 114 receives the input load current, then the magnetic flux of inductor 100 in the coupled state traverses a counterclockwise path. If current is switched into both windings, the direction of flow of the magnetic flux of the inductor 100 in the coupled state may be determined by a sum or part of sum of the flux for the individual windings.

Referring now to Figure 1E, an equivalent diagram of the inductor in the coupled state corresponding to Figure 1D is shown. In this diagram, because the bridge 130 is saturated, the reluctance path through the bridge is too high to pass any substantial amount of magnetic flux. Consequently, as shown by arrow 140, the inductors L₁ and L₂ operate in a inversely coupled state having a magnetic flux direction and coupled inductance value based on which switch SW1 or SW2 is open/closed. In Figure 1E, the letter M indicates the formation of a mutual inductance between the core windings. Also, the dots adjacent the windings denote the voltage polarity with respect to the windings. For example, when current enters the dot corresponding to the windings of L₁, energy is induced in the windings of L₂ and current is output along the circuit path coupled to the dot of this second winding.

As described above, the EI inductor configuration enables dual state performance. However, manufacturing tolerances may result in non-ideal performance of the inductor. An example of manufacturing issues is shown in Figure 2A. As shown, the inductor 200 includes a first core 210 and a second core 220. Similar to above, the first core 210 includes a main body 211 with three protrusions 212, 213, and 214. Windings may be provided around protrusions 212 and 214. Additionally, gaps G₁ and G₂ may be provided between protrusion 212 and body 221 and protrusion 214 and body 221. However, a third gap G₃ is present between the bridge 230 and the body 221. This gap increases the reluctance and negatively impacts performance.

The third gap G₃ may be caused by any number manufacturing tolerance issues. For example, dimensions of the bridge 230 may be non-uniform. That is, a thickness decrease in the bridge 230 may result in the formation of the third gap G₃. Also surface roughness at the bridge 230 or the body 221 may result in the formation of gaps as well. In some instances, the third gap G₃ may be up to approximately 30μm or less. As used herein, “approximately” refers to a range of values within ten percent of the stated value. For example, approximately 30μm may refer to a range between 27μm and 33μm.

Referring now to Figure 2B, a graph of inductance versus DC bias for an ideal inductor (line 205) and an EI inductor (line 204) is shown. As shown, the ideal inductor has a discernible step 206 where there is a sharp transition between the decoupled light load (higher inductance) and coupled heavy load (lower inductance) . The sharp step enhances efficiency of the inductor and provides improved performance to the voltage regulator that uses such an inductor. In contrast, the EI inductor includes a shallow slope 207 at the junction between the decoupled light load and the coupled heavy load. As such, performance is less than the ideal case.

Accordingly, embodiments disclosed herein bring the inductor closer to the ideal case. More particularly, embodiments disclosed herein improve inductor performance by eliminating the formation of gaps adjacent to the bridge. Instead of discrete cores that are brought towards each other with the hope of eliminating gaps, the improved inductors disclosed herein use a central core that has a monolithic bridge structure. That is, the inductor has a pair of end regions that are physically connected to each other by an integrated bridge.

Referring now to Figure 3, a cross-sectional illustration of an inductor 300 is shown, in accordance with an embodiment. In an embodiment, the inductor 300 comprises a three core construction. The three cores include a first outer core 340A, a second outer core 340B, and a center (or middle) core 350. The first outer core 340A and the second outer core 340B may have C-shaped structures. More particularly, the opening of the C-shape may face the center core 350. The first outer core 340A and the second outer core 340B may comprise a magnetic material, such as a ferrite. In an embodiment, an electrically conductive winding 315 may be provided around the first outer core 340A, and an electrically conductive routing 316 may be provided around the second outer core 340B.

In an embodiment, the center core 350 may comprise end portions 351 and 353 that are directly coupled together by a bridge 352. The bridge 352 and the end portions 351 and 353 may be formed of a single monolithic structure so that the end portions 351 and 353 and the bridge 352 are a single part. For example, the center core 350 may comprise a magnetic material, such as a ferrite. The bridge 352 may have a width that is narrower than the width of the end portions 351 and 353. That is, a width of end portion 351 and a width of end portion 353 may both be wider than a width of the bridge 352. In some embodiments, the bridge 352 may have at least one confined dimension that is an order of magnitude smaller than a width or a length of the end portions 351 and 353. The dimensions of the bridge 352 may be set in order to provide full magnetic saturation at a given load. This allows for the inductor 300 to switch between a coupled state and a decoupled state, as will be described in greater detail below.

In an embodiment, the inductor 300 may include gaps between the outer cores 340A and 340B and the central core 350. For example, the arms of the C-shape of the first outer core 340A may be separated from the end portions 351 and 353 of the central core by gaps G₁ and G₂. Similarly, gaps G₃ and G₄ may separate the arms of the C-shape of the second outer core 340B from the end portions 351 and 353. The gaps G₁ –G₄ may each be approximately 100μm or less, or approximately 20μm or less according to inductance parameter design requirement.

Referring now to Figures 4A and 4B, operation of an inductor 400 in a decoupled state (Figure 4A) and in a coupled state (Figure 4B) is shown, in accordance with an embodiment. The inductor 400 may be similar to the inductor 300 in Figure 3. For example, the inductor 400 may include three magnetic cores (i.e., outer cores 440A and 440B, and center core 450) . The center core 450 may include end portions 451 and 453 that are coupled together by a bridge 452 to form a single monolithic piece. The first outer core 440A may be separated from the center core 450 by gaps G₁ and G₂, and the second outer core 440B may be separated from the center core 450 by gaps G₃ and G₄.

Referring now to Figure 4A, a cross-sectional illustration of the inductor 400 in a decoupled state is shown, in accordance with an embodiment. As shown, windings 415 around the first outer core 440A operate as a first inductor, and the windings 416 around the second outer core 440B operate as a second inductor. Because the first and second inductors operate separately, the inductor 400 is considered to be in a decoupled state.

This decoupled state occurs automatically based on a size of the load current flowing through the inductor in relation to a magnetic permeability of the bridge 452. In the illustrated example, when the load current is less than a predetermined threshold value, the bridge 452 is in a magnetically unsaturated state. As a result, the magnetic flux 431 from the first inductor flows along a low magnetic reluctance path that passes through the central core 450, including the bridge 452. Similarly, magnetic flux 432 from the second inductor passes through the central core 450, including the bridge 452.

Also, the magnetic flux 431 and 432 may flow in opposite directions. This may be accomplished by sending current through the windings in different directions. For example, current may be sent into the winding 415 from the side and exit from the top, and current may be sent into the winding 416 from the top and exit from the side.

Referring now to Figure 4B, a cross-sectional illustration of the inductor 400 operating in a coupled state is shown, in accordance with an embodiment. In this state, the windings 415 around the first outer core 440A and the windings 416 around the second outer core 440B produce magnetic flux 437 and 438 which is added together to form the flux (and thus the inductance) of a coupled inductor 400. If the flux 437 and 438 from the windings flows in the same direction, the net flux (and thus inductance) in the coupled state will be greater than the individual inductances of the windings. Conversely, if the flux 437 and 438 from the windings flows in different directions (as shown in Figure 4B) , some of the flux 437 from one winding will cancel the flux 438 from the other winding. This may produce a net flux (and inductance) in the coupled state that is less than one or both of the windings taken individually.

This coupled state occurs automatically based on a size of the load current in relation to the magnetic permeability of the bridge 452. In this example, when the load current is greater than the predetermined threshold value, the bridge 452 is magnetically saturated. As a result, the bridge 452 functions essentially as a non-magnetic material (e.g., one that is not magnetically permeable such as air) and one part of the magnetic flux 437 and 438 will flow through the central core 450, but a substantial amount of the flux will not flow through the bridge 452. The other part of the magnetic flux 437 and 438 will flow through the outer cores 440A and 440B.

In operation, the current may be switched into both or only one of the windings. If the current is only switched into one of the windings, the direction of flow of the magnetic flux of the inductor in the coupled state is determined by the inductor winding that receives the input current. For example, if the winding 415 around the first outer core 440A receives the input load current, then the magnetic flux of the inductor 400 in the coupled state traverses a clockwise path. If the winding 416 around the second outer core 440B receives the input load current, then the magnetic flux of inductor 400 in the coupled state traverses a counterclockwise path. If current is switched into both windings, the direction of flow of the magnetic flux of the inductor 400 in the coupled state may be determined by a sum or part of a sum of the flux for the individual windings 415 and 416.

Referring now to Figure 4C, a graph of inductance versus DC bias is shown, in accordance with an embodiment. As shown, the dashed line 404 represents the non-ideal case, similar to inductors illustrated and described above. As shown, the line 404 includes a gentle slope 407 between the light load and heavy load operation. In contrast, line 402 illustrates the electrical behavior of an inductor similar to the ones described with respect to Figure 3 and Figures 4A and 4B. As shown, a steeper slope 403 is provided. While the slope 403 may not be a perfectly vertical step (which occurs in the perfectly ideal case) , the slope 403 is significantly improved. Therefore, a transition between a decoupled state and a coupled state is made more efficient and improves the performance of a voltage regulator that uses such an inductor.

Referring now to Figures 5A –5C, a series of cross-sectional illustrations of a central core 550 is shown, in accordance with various embodiments. The plane of the cross-sections in Figures 5A –5C may be along line 5-5’ in Figure 3.

Referring now to Figure 5A, a cross-sectional illustration of a central core 550 is shown, in accordance with an embodiment. As shown, the end portions 551 and 553 are coupled together by a bridge 552. As shown, the bridge 552 has a width that is significantly smaller than widths of the end portions 551 and 553.

Referring now to Figure 5B, a cross-sectional illustration of a central core 550 is shown, in accordance with an additional embodiment. As shown, a plurality of bridges 552A and 552B are provided between the end portions 551 and 553. While two bridges 552A and 552B are shown, it is to be appreciated that any number of bridges 552 may be provided between the end portions 551 and 553.

Referring now to Figure 5C, a cross-sectional illustration of a central core 550 is shown, in accordance with an additional embodiment. As shown, the bridge 552 may have a width that substantially equals the width of the end portions 551 and 553. It is to be appreciated that the confined dimension of the bridge 552 is provided out of the plane of Figure 5C. For example, the confined dimension is illustrated in the plane shown in Figure 3.

In previous embodiments, inductors that are configured for dual state operation are shown. However, it is to be appreciated that embodiments disclosed herein are also applicable to single state inductors. For example, inductors that only operate in a decoupled state may also benefit from the three core construction embodiments described in greater detail herein.

For example, a single mode inductor 600 is shown in Figure 6. As shown, a first core 610 with an E-shape is opposite from an second core 620 with an I-shape. The first core 610 may include a main body 611 with protrusions 612, 613, and 614. As shown, the central protrusion directly contacts body 621 of the second core 620. This leaves a gap G₁ between the protrusion 612 and the body 621 and a gap G₂ between the protrusion 614 and the body 621. Flux 631 and 632 may both pass through the central protrusion 613. Since there is no reduced dimension bridge between protrusion 613 and the second core 620, only the decoupled state is enabled.

While the inductor 600 works, it is to be appreciated that the inductor structure is not mechanically stable. More particularly, protrusion 613 functions as a pivot point. This allows for the first core 610 to rotate. In some instances the rotation of the first core 610 may result in one of the gaps G₁ or G₂ being closed. That is, the central protrusion 613 and one of the protrusions 612 or 614 may both contact the second core 620.

Accordingly, embodiments disclosed herein may include an inductor 700 with a three core structure, such as shown in Figure 7A. As shown, outer cores 740A and 740B are C-shaped and face a central core 750. The central core 750 may have a uniform width body 751. For example, the body 751 may have a rectangular cross-section. Since there is no confined bridge along the central core 750, flux 731 and 732 flow in a decoupled state. The central core 750 may be spaced away from the first outer core 740A by gaps G₁ and G₂, and the central core 750 may be spaced away from the second outer core 740B by gaps G₃ and G₄. Since there is no pivot point, the inductor 700 is more mechanically stable than the one shown in Figure 6.

Referring now to Figure 7B, a cross-sectional illustration of an inductor 700 is shown, in accordance with an additional embodiment. In an embodiment, the inductor 700 in Figure 7B may be substantially similar to the inductor 700 in Figure 7A, with the exception of the shape of the body 751 of the central core 750. Instead of having a rectangular cross-section, the body 751 has an I-shaped cross section. Since there is no pivot point, the inductor 700 is more mechanically stable than the one shown in Figure 6.

Referring now to Figure 8 one embodiment of an internal configuration of a device that includes a voltage regulator 872 with a three core architecture is shown, in accordance with an embodiment. In an embodiment, the device includes a voltage source 871, a voltage regulator 872, and one or more platforms 870₁, 870₂, and 870₃, which may have different voltage requirements to support different functions or operations in the terminal. For example, when the electronic device is a mobile terminal, one platform 870₁ may operate the communication circuits of the terminal, another platform 870₂ may operate a media player of the terminal, and the third platform 870₃ may operate a camera function.

The coupling between the voltage regulator 872 and platforms 870 may be selectively switched to change the current passing through the inductor of the regulator 872. The inductor may be one in accordance with any of the aforementioned embodiments. For example the inductor may be a three core inductor with a bridge in the middle core. If the voltage regulator 872 has an inductor which corresponds to the one shown in Figure 3, then L1 may be switched by switch SW1 to generate a first voltage to platform 870₁ and L2 may be switched by SW2 to generate a second voltage to platform 870₂. Both inductors may be in the decoupled state at this time, i.e., the magnetic flux through the at least one bridge is at an unsaturated level. In the coupled state, a mutual inductance formed by L1 and L2 may be used to generate a third voltage to platform 870₃ when switch SW3 closes. The magnetic flux through the at least one bridge may be at a saturated level at this time. Alternatively in the coupled state, all the bridges may be saturated. If one of the bridges is not saturated, the flux of L1 and L2 may not pass across each other, but across the unsaturated bridge at the center core.

In accordance with one embodiment, voltages V1, V2, and V3 supplied to the different platforms 870 may be different from each other. As in the previously described embodiments, the amount of magnetic flux through the bridge may be controlled, for example, based on the current through one or more of the windings, the magnetic permeability of the bridge, and the spacing between the bridges when a multi-bridge embodiment of the inductor is used.

Referring now to Figure 9, a cross-sectional illustration of an electronic system 990 is shown, in accordance with an embodiment. The electronic system 990 may include a board 991, such as a printed circuit board (PCB) or the like. The board 991 may be coupled to a package substrate 993 by interconnects 992. The interconnects 992 may be solder balls, sockets, or the like. The package substrate 993 may include a core (not shown) . In an embodiment, one or more dies 995 may be coupled to the package substrate 993 by interconnects 994. The interconnects 994 may be solder balls, copper bumps, or any other first level interconnect (FLI) architecture. The dies 995 may comprise compute dies such as, but not limited to, a central processing unit (CPU) , a graphics processing unit (GPU) , an XPU, a system on a chip (SoC) , a communications die, or a memory die.

In an embodiment, one or more voltage regulators 980 may be integrated with the electronic system 990. The voltage regulators 980 may each include one or more inductors, such as those described in greater detail herein. For example, the inductors may include three magnetic cores. In some instances, the central core comprises a bridge that allows for either decoupled operation or coupled operation of the inductor.

In an embodiment, one or more voltage regulators 980 may be provided on the board 991. Other embodiments may include one or more voltage regulators 980 that are integrated within (e.g., embedded in) the package substrate 993. In yet another embodiment, one or more voltage regulators 980 may be provided on the package substrate 993.

Figure 10 illustrates a computing device 1000 in accordance with one implementation of the invention. The computing device 1000 houses a board 1002. The board 1002 may include a number of components, including but not limited to a processor 1004 and at least one communication chip 1006. The processor 1004 is physically and electrically coupled to the board 1002. In some implementations the at least one communication chip 1006 is also physically and electrically coupled to the board 1002. In further implementations, the communication chip 1006 is part of the processor 1004.

These other components include, but are not limited to, volatile memory (e.g., DRAM) , non-volatile memory (e.g., ROM) , flash memory, a graphics processor, a digital signal processor, a crypto processor, a chipset, an antenna, a display, a touchscreen display, a touchscreen controller, a battery, an audio codec, a video codec, a power amplifier, a global positioning system (GPS) device, a compass, an accelerometer, a gyroscope, a speaker, a camera, and a mass storage device (such as hard disk drive, compact disk (CD) , digital versatile disk (DVD) , and so forth) .

The communication chip 1006 enables wireless communications for the transfer of data to and from the computing device 1000. The term “wireless” and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium. The term does not imply that the associated devices do not contain any wires, although in some embodiments they might not. The communication chip 1006 may implement any of a number of wireless standards or protocols, including but not limited to Wi-Fi (IEEE 802.11 family) , WiMAX (IEEE 802.16 family) , IEEE 802.20, long term evolution (LTE) , Ev-DO, HSPA+, HSDPA+, HSUPA+, EDGE, GSM, GPRS, CDMA, TDMA, DECT, Bluetooth, derivatives thereof, as well as any other wireless protocols that are designated as 3G, 4G, 5G, and beyond. The computing device 1000 may include a plurality of communication chips 1006. For instance, a first communication chip 1006 may be dedicated to shorter range wireless communications such as Wi-Fi and Bluetooth and a second communication chip 1006 may be dedicated to longer range wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE, Ev-DO, and others.

The processor 1004 of the computing device 1000 includes an integrated circuit die packaged within the processor 1004. In some implementations of the invention, the integrated circuit die of the processor may be part of an electronic package with a voltage regulator that includes a three core inductor with a bridge that enables either coupled operation or decoupled operation, in accordance with embodiments described herein. The term “processor” may refer to any device or portion of a device that processes electronic data from registers and/or memory to transform that electronic data into other electronic data that may be stored in registers and/or memory.

The communication chip 1006 also includes an integrated circuit die packaged within the communication chip 1006. In accordance with another implementation of the invention, the integrated circuit die of the communication chip may be part of electronic package with a voltage regulator that includes a three core inductor with a bridge that enables either coupled operation or decoupled operation, in accordance with embodiments described herein.

In an embodiment, the computing device 1000 may be part of any apparatus. For example, the computing device may be part of a personal computer, a server, a mobile device, a tablet, an automobile, or the like. That is, the computing device 1000 is not limited to being used for any particular type of system, and the computing device 1000 may be included in any apparatus that may benefit from computing functionality.

The above description of illustrated implementations of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific implementations of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.

These modifications may be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific implementations disclosed in the specification and the claims. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.

Example 1: an inductor, comprising: a first core; a second core; and a third core between the first core and the second core, wherein a first gap is provided between the first core and the third core and a second gap is provided between the second core and the third core, and wherein the third core comprises: a first portion with a first width; a second portion with a second width; and a third portion with a third width between the first portion and the second portion, wherein the third width is smaller than both of the first width and the second width.

Example 2: the inductor of Example 1, wherein the first core and the second core have C-shaped cross-sections.

Example 3: the inductor of Example 1 or Example 2, wherein a first electrically conductive winding is provided around the first core, and a second electrically conductive winding is provided around the second core.

Example 4: the inductor of Examples 1-3, wherein the third core is a monolithic structure.

Example 5: the inductor of Examples 1-4, wherein the first core, the second core, and the third core comprise magnetic materials.

Example 6: the inductor of Examples 1-5, wherein the third portion comprises a plurality of sections.

Example 7: the inductor of Examples 1-6, wherein the third core is I shaped.

Example 8: the inductor of Examples 1-7, wherein the inductor operates in a first state when the third portion is not magnetically saturated and in a second state when the third portion is magnetically saturated.

Example 9: inductor of Example 8, wherein the first state is a decoupled state, and wherein the second state is a coupled state.

Example 10: the inductor of Examples 1-9, wherein the first gap and the second gap are both up to approximately 100μm wide.

Example 11: an inductor, comprising: a first core, wherein the first core has a C-shaped cross-section; a second core, wherein the second core has the C-shaped cross- section; and a third core between the first core and the second core, wherein the third core is a monolithic structure.

Example 12: the inductor of Example 11, wherein the third core comprises an I-shaped cross-section.

Example 13: the inductor of Example 11 or Example 12, wherein the first core is separated from the third core by a first gap, and wherein the second core is separated from the third core by a second gap.

Example 14: the inductor of Example 13, wherein the first core opens up towards the third core, and wherein the second core opens up towards the third core.

Example 15: the inductor of Example 13, wherein the first gap and the second gap are approximately 100μm wide or smaller.

Example 16: the inductor of Examples 11-15, wherein the first core, the second core, and the third core comprise magnetic material.

Example 17: the inductor of Examples 11-16, further comprising: a first electrically conductive winding around the first core; and a second electrically conductive winding around the second core.

Example 18: an electronic system, comprising: a board; a package substrate coupled to the board; a die coupled to the package substrate; and a voltage regulator, wherein the voltage regulator comprises: an inductor with three magnetic cores configured to provide a decoupled inductance or a coupled inductance.

Example 19: the electronic system of Example 18, wherein the voltage regulator is provided on the board, on the package substrate, or embedded in the package substrate.

Example 20: the electronic system of Example 18 or Example 19, wherein the electronic system is part of a personal computer, a server, a mobile device, a tablet, or an automobile.

Claims

An inductor, comprising:

a first core;

a second core; and

a third core between the first core and the second core, wherein a first gap is provided between the first core and the third core and a second gap is provided between the second core and the third core, and wherein the third core comprises:

a first portion with a first width;

a second portion with a second width; and

a third portion with a third width between the first portion and the second portion, wherein the third width is smaller than both of the first width and the second width.
The inductor of claim 1, wherein the first core and the second core have C-shaped cross-sections.
The inductor of claim 1, wherein a first electrically conductive winding is provided around the first core, and a second electrically conductive winding is provided around the second core.
The inductor of claim 1, wherein the third core is a monolithic structure.
The inductor of claim 1, wherein the first core, the second core, and the third core comprise magnetic materials.
The inductor of claim 1, wherein the third portion comprises a plurality of sections.
The inductor of claim 1, wherein the third core is I shaped.
The inductor of claim 1, wherein the inductor operates in a first state when the third portion is not magnetically saturated and in a second state when the third portion is magnetically saturated.
The inductor of claim 8, wherein the first state is a decoupled state, and wherein the second state is a coupled state.
The inductor of claim 1, wherein the first gap and the second gap are both up to approximately 100μm wide.
An inductor, comprising:

a first core, wherein the first core has a C-shaped cross-section;

a second core, wherein the second core has the C-shaped cross-section; and

a third core between the first core and the second core, wherein the third core is a monolithic structure.
The inductor of claim 11, wherein the third core comprises an I-shaped cross-section.
The inductor of claim 11, wherein the first core is separated from the third core by a first gap, and wherein the second core is separated from the third core by a second gap.
The inductor of claim 13, wherein the first core opens up towards the third core, and wherein the second core opens up towards the third core.
The inductor of claim 13, wherein the first gap and the second gap are approximately 100μm wide or smaller.
The inductor of claim 11, wherein the first core, the second core, and the third core comprise magnetic material.
The inductor of claim 11, further comprising:

a first electrically conductive winding around the first core; and

a second electrically conductive winding around the second core.
An electronic system, comprising:

a board;

a package substrate coupled to the board;

a die coupled to the package substrate; and

a voltage regulator, wherein the voltage regulator comprises:

an inductor with three magnetic cores configured to provide a decoupled inductance or a coupled inductance.
The electronic system of claim 18, wherein the voltage regulator is provided on the board, on the package substrate, or embedded in the package substrate.
The electronic system of claim 18, wherein the electronic system is part of a personal computer, a server, a mobile device, a tablet, or an automobile.