Compact Inductor with Planar Cores Reducing Magnetic Flux Leakage
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Solution Overview
Problem
Inductors in electrical devices face challenges due to significant magnetic flux linkage, electromagnetic radiation leakage, and heat generation, which require isolation within a chassis, increasing cost and size.
Innovation Solution
A compact inductor design featuring planar cores with electrical windings between them, reducing magnetic flux and electromagnetic radiation leakage, and allowing for efficient cooling, thereby reducing the required buffer space and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional inductor design with magnetic teeth is used, then inductance is achieved, but magnetic flux leakage and electromagnetic radiation increase, requiring larger isolation space
Solution Approach 1:
The inductor is segmented into multiple planar cores (first planar core and second planar core) arranged in a specific configuration. This segmentation allows the magnetic flux to be contained within each planar core structure, reducing overall magnetic flux leakage and electromagnetic radiation while maintaining the required inductance value.
Solution Approach 2:
The patent transitions from traditional three-dimensional magnetic core structures to two-dimensional planar cores. This dimensional change enables a more compact inductor design that reduces the volume required for magnetic flux containment while minimizing harmful electromagnetic radiation through the planar geometry.
2Use of energy by stationary object
If traditional inductor design is used, then inductance is achieved, but heat generation requires active cooling, increasing operational cost
Solution Approach 1:
The planar core structure with its increased surface area-to-volume ratio enables the inductor to self-cool more effectively through passive heat dissipation. The design inherently provides better thermal management without requiring active cooling systems, reducing operational energy costs.
3Reliability
If magnetic teeth are included between planar cores, then inductance is enhanced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts or removes the magnetic teeth component from the traditional inductor design. By eliminating magnetic teeth while maintaining planar core structures, the design achieves the required inductance performance through the planar core geometry and winding configuration alone, significantly reducing structural complexity and manufacturing difficulty.
4Object-generated harmful factors
If isolation space is increased for magnetic flux containment, then electromagnetic radiation is reduced, but chassis size and cost increase
Solution Approach 1:
By transitioning to two-dimensional planar cores, the inductor achieves efficient magnetic flux containment within a smaller three-dimensional footprint. This dimensional change allows the inductor to maintain electromagnetic radiation control without requiring excessive isolation space in the chassis.
Solution Approach 2:
The segmented planar core structure contains magnetic flux within each planar segment, preventing flux leakage into surrounding areas. This segmentation approach reduces the isolation space required compared to traditional monolithic core designs.
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 design integrates common mode and differential mode inductance in a smaller volume at reduced cost, with efficient cooling and minimized magnetic flux leakage, reducing the operational and material costs of electrical devices.
Implementation Method 1
Inductors are commonly used in electrical devices and are often included in power supplies. Because inductors generate magnetic flux and/or electromagnetic radiation
Implementation Method 2
the magnetic flux generated by an inductor often makes it difficult to cool the inductor using passive means
Data Source
AI summary
For reducing volume requirements and magnetic flux leakage, a compact inductor includes a first planar core with a first core thickness along a first axis orthogonal to a plane of the first planar core. In addition, the inductor includes a second planar core disposed parallel to the first planar core with a second core thickness along the first axis. The inductor further includes a plurality of electrical windings disposed between and adjacent to an inside plane of the first planar core and an inside plane of the second planar core. The electrical windings may include insulated electrical wires. No magnetic teeth may be disposed between the first planar core and the second planar core. The first axis is parallel to a magnetic axis of each electrical winding.