Banked Winding Inductor with Optimized Core Gap
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Solution Overview
Problem
Inductor components with closed magnetic circuits and gaps improve direct-current superimposition characteristics but reduce inductance values, while multi-layer windings enhance inductance but decrease impedance at higher frequencies, limiting their effectiveness in high-frequency applications.
Innovation Solution
An inductor component with a drum core and plate core made of magnetic material, featuring aligned banked windings with a specific gap between the plate core and flange portions, and a return section in the winding configuration to improve direct-current superimposition characteristics and maintain high inductance at higher frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap is introduced between the drum core and plate core to improve direct-current superimposition characteristics, then the magnetic saturation is suppressed, but the inductance value is reduced
Solution Approach 1:
The patent optimizes the gap distance between the drum core and plate core to a specific range (20-50 μm) to balance two competing requirements: a sufficient gap to suppress magnetic saturation and improve direct-current superimposition characteristics, while maintaining a small enough gap to preserve inductance value. This parameter optimization resolves the contradiction by finding the optimal compromise point.
2Quantity of substance
If the number of wire turns is increased to compensate for reduced inductance, then the inductance value is restored, but the available winding space is exceeded
Solution Approach 1:
The patent transitions from traditional single-layer or simple multi-layer winding to banked winding, which arranges multiple winding sections in a three-dimensional configuration around the drum core. This dimensional change allows achieving the required number of turns within the limited winding space by utilizing the radial and axial dimensions more effectively.
3Quantity of substance
If banked winding is used to increase the number of turns in limited space, then the inductance value is increased, but the self-resonant frequency is lowered and impedance decreases at higher frequencies
Solution Approach 1:
The patent introduces a ground section (grounded shielding section) at specific locations within the banked winding structure to suppress parasitic capacitance and high-frequency resonance. This local modification improves the high-frequency impedance characteristics without significantly affecting the overall inductance value, thereby resolving the contradiction between inductance and self-resonant frequency.
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
The solution achieves enhanced direct-current superimposition characteristics, increased inductance at higher frequencies, reduced capacitance, and stable impedance characteristics up to high frequencies exceeding 1 GHz, making it suitable for high-frequency applications like choke coils.
Implementation Method 1
An inductor component including a drum core made of a magnetic material can achieve high inductance by bonding a plate core made of a magnetic material to the drum core such that the plate core spans a distance between a pair of flange portions in the drum core and thus forming a closed magnetic circuit
Implementation Method 2
wire wound around a winding core portion of the drum core
Data Source
AI summary
An inductor component includes a drum core including a winding core portion extending along a longitudinal direction and a pair of flange portions disposed on end portions of the winding core portion, a plate core bonded to the pair of flange portions, and a wire wound around the winding core portion. The drum core and the plate core are made of a magnetic material. An average distance between the plate core and the pair of flange portions is no less than about 20 μm and no more than about 50 μm. The wire includes aligned banked winding portions arranged along the longitudinal direction and more than half of a total number of turns of the wire belong to the aligned banked winding portions.