Adjustable Inductor With Composite Core And Conductive Plug
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Solution Overview
Problem
Current adjustable inductors face limitations in adjusting inductance across low and high voltage and current conditions, often introducing unwanted parasitic electrical properties and mechanical deformation, and ferromagnetic materials can saturate under high currents, leading to non-linear effects.
Innovation Solution
An adjustable inductor design featuring a core with both non-conductive and conductive portions, utilizing a screw-like construction and electrical plane for shielding, allowing for a wide range of inductance without mechanical deformation, and using materials like ferromagnetic or dielectric materials based on application needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ferromagnetic material is used to adjust inductance, then inductance can be changed, but the material saturates under high currents causing non-linear effects
Solution Approach 1:
The patent uses a composite core structure combining ferromagnetic material (for high permeability and high inductance) and non-conductive material (for mechanical support and electrical insulation). This composite approach allows the ferromagnetic portion to provide the desired inductance adjustment while the non-conductive portion prevents saturation-related non-linearities by providing structural support without contributing to magnetic saturation.
Solution Approach 2:
The core is divided into multiple portions: a ferromagnetic portion for providing high permeability and inductance, and a non-conductive portion for providing mechanical support and electrical insulation. This segmentation allows each material to perform its optimal function without the drawbacks of using a single material throughout the entire core structure.
2Adaptability or versatility
If coil is compressed or expanded to adjust inductance, then inductance changes, but mechanical deformation occurs and coil may be damaged
Solution Approach 1:
The patent replaces the mechanical compression/expansion method with a core insertion/removal mechanism. Instead of deforming the coil mechanically, the inductance is adjusted by inserting or removing the core from the coil, which changes the magnetic path length and thus the inductance without applying mechanical stress to the coil windings.
Solution Approach 2:
The core is designed to be movable relative to the coil, allowing dynamic adjustment of inductance by changing the position of the core within the coil. This dynamic adjustment mechanism enables continuous inductance variation without mechanical deformation of the coil structure.
3Adaptability or versatility
If trace is moved along coil to adjust inductance, then inductance changes, but excess wire coils remain introducing parasitic properties
Solution Approach 1:
The patent extracts the unwanted excess wire coils from the inductor structure by designing the core to extend beyond the coil ends. This allows the magnetic flux to be confined within the coil region and prevents the excess wire from creating parasitic inductance or capacitance effects that would occur if the wire continued beyond the active inductor region.
4Adaptability or versatility
If open air is used for voltage stand-off, then low voltage operation is possible, but high voltage conditions cannot be handled
Solution Approach 1:
The patent changes the electrical parameter of the core material by using non-conductive material with appropriate dielectric strength to handle high voltages. This allows the inductor to operate reliably across a wide voltage range from low to high voltages, as the non-conductive core provides the necessary electrical insulation that air cannot provide at high voltage levels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid optimization of high power radio frequency modules and antennas with minimal parasitic effects, providing near-zero inductance options and maintaining contact with all windings to minimize unwanted electrical properties, allowing for repeatable and efficient tuning across various voltage and current conditions.
Implementation Method 1
The second portion (conductive plug) is configured to electrically short selected windings of the coil
Implementation Method 2
The first portion (insulator) is configured to provide electrical insulation between the conductive plug and the coil
Data Source
AI summary
Embodiments of the invention disclose methods of assembling and using an adjustable inductor to vary inductance. An adjustable inductor, according to embodiments of the invention, includes a wire coil configured to mount on a first side of a conductive plate. The wire coil is conductive and is a plurality of windings. A core has a first portion and a second portion. The first and second portions are configured with a plurality of grooves for threading engagement with the plurality of windings of the wire coil. The threading engagement attaches the core to the plurality of windings of the wire coil. Rotating the core results in varied inductance.