Chip Inductor with Segmented Magnetic Core for Saturation Resistance
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Solution Overview
Problem
Chip-type inductors have inadequate magnetic force characteristics, limiting their use to low-current applications due to poor heat release and magnetic saturation issues, which restrict their inductance value and operational performance.
Innovation Solution
The design includes a magnetic material body with internal and external magnetic materials arranged to maintain uniform cross-sectional areas for magnetic flux flow, and a conductive pattern that surrounds the internal magnetic material, with external magnetic material gaps to prevent saturation, allowing for efficient heat dissipation and increased inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If chip-type inductor uses conventional magnetic material structure, then device complexity is reduced, but magnetic force characteristics are inadequate and magnetic saturation occurs
Solution Approach 1:
The magnetic material body is segmented into internal magnetic material and external magnetic material with distinct functions. The internal magnetic material provides high permeability for magnetic flux concentration, while the external magnetic material provides magnetic path and heat dissipation. This segmentation resolves the contradiction by achieving superior magnetic force characteristics through functional division rather than using a single complex material structure.
Solution Approach 2:
The inductor employs a composite magnetic material structure combining internal magnetic material (with high permeability) and external magnetic material (with heat dissipation properties). This composite approach enables the device to achieve both strong magnetic force characteristics and effective heat management without requiring overly complex single-material structures.
2Power
If chip-type inductor increases inductance value for high-current applications, then operational performance improves, but heat release characteristics degrade
Solution Approach 1:
Different regions of the magnetic material body are assigned different properties: the internal magnetic material is optimized for magnetic flux concentration (high permeability) to support high inductance, while the external magnetic material is optimized for heat dissipation. This local quality differentiation allows the inductor to handle high currents with improved inductance while maintaining effective heat release characteristics.
Solution Approach 2:
The external magnetic material acts as an intermediary that serves dual functions: providing a magnetic path for flux flow and facilitating heat dissipation from the internal magnetic material and conductive pattern. This intermediary structure enables the inductor to achieve high power handling capability without compromising heat release.
3Reliability
If chip-type inductor uses uniform magnetic material structure, then manufacturing is simplified, but magnetic flux flow becomes non-uniform causing saturation
Solution Approach 1:
The magnetic material body is divided into internal and external magnetic materials with distinct roles. The internal magnetic material concentrates magnetic flux, while the external magnetic material provides a distributed magnetic path that ensures uniform flux flow. This segmentation improves magnetic flux distribution and prevents saturation without requiring overly complex manufacturing processes, as each segment can be manufactured separately and then assembled.
4Power
If chip-type inductor increases magnetic permeability for higher inductance, then inductance value improves, but magnetic saturation occurs more easily
Solution Approach 1:
The internal magnetic material is designed with high permeability to achieve high inductance values, while the external magnetic material provides a distributed magnetic path that prevents flux concentration and saturation. This local quality differentiation allows the inductor to maintain high inductance without sacrificing saturation resistance, as the high-permeability material is localized and its flux is distributed through the external magnetic material structure.
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
This configuration enhances the inductance value and operational characteristics, enabling the inductor to handle higher currents and preventing magnetic saturation, making it suitable for power applications with improved heat release and performance.
Implementation Method 1
magnetic fluxes of a magnetic field produced by current flowing along the conductive pattern
Implementation Method 2
internal and external magnetic materials arranged to maintain uniform cross-sectional areas for magnetic flux flow
Implementation Method 3
external magnetic material gaps to prevent saturation
Implementation Method 4
improved heat release characteristics
Data Source
AI summary
A chip-type inductor comprising includes internal magnetic material, external magnetic material disposed on opposing sides of the internal magnetic material, and a conductor formed in a space between the internal and external magnetic material. The internal and external magnetic materials form a magnetic path along which magnetic flux of a magnetic field produced by current flowing along the conductor flows. According to at least one embodiment, the flow cross-sectional area of the magnetic flux in the internal magnetic material is at least substantially equal to a sum of the flow cross-sectional areas in the external magnetic materials.