Composite Inductor with Ferrite and Non-Magnetic Layers
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Solution Overview
Problem
Existing inductors face challenges in achieving a balance between minimizing size, maximizing saturation current, and minimizing DC resistance while maintaining high efficiency and inductance, especially in applications like DC/DC converters, where prior art fails to meet these requirements effectively.
Innovation Solution
The inductor design incorporates a coil with a non-ferrite layer and adjacent ferrite layers, where the ferrite layers enhance permeability to increase inductance and reduce DC resistance, and a non-magnetic layer is used to manage magnetic fields, allowing for higher saturation current and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the size of inductor is minimized to fit in limited printed circuit board, then the area occupied is reduced, but the saturation current decreases and DC resistance increases
Solution Approach 1:
The inductor uses a composite magnetic core structure combining ferrite material and non-magnetic material. The ferrite layer provides high permeability for enhanced inductance, while the non-magnetic material maintains structural integrity and allows compact winding. This composite approach enables smaller size while maintaining or improving saturation current and DC resistance characteristics.
Solution Approach 2:
The patent transitions from traditional planar inductor designs to a three-dimensional layered structure with ferrite and non-magnetic materials stacked in different dimensions. This dimensional change allows more efficient use of space, enabling compact footprint while maintaining electrical performance through optimized magnetic flux paths in multiple layers.
2Power
If ferrite material is used to increase inductance, then the inductance value increases, but the saturation current capability may be reduced
Solution Approach 1:
The inductor implements local quality by using ferrite material specifically in regions where high permeability is needed to enhance inductance, while using non-magnetic materials in areas where high saturation current capability is required. This spatial differentiation of material properties allows simultaneous optimization of both inductance and saturation current characteristics.
Solution Approach 2:
By combining ferrite and non-magnetic materials in a layered composite structure, the inductor achieves both high inductance (from ferrite) and high saturation current capability (from non-magnetic material regions). The composite structure allows each material to contribute its advantageous properties without the drawbacks of using either material alone.
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 design results in an inductor with higher inductance, saturation current, and lower DC resistance compared to conventional inductors, improving efficiency and preventing inductance loss during heavy-loaded currents, while maintaining a compact size suitable for surface mounting technology.
Implementation Method 1
the ferrite layers enhance permeability to increase inductance and reduce DC resistance
Implementation Method 2
an inductor comprises a magnetic core and a coil
Data Source
AI summary
An inductor comprises a coil, a non-ferrite layer, two electrodes, a first ferrite layer, and a second ferrite layer, where the coil is encapsulated by the non-ferrite layer having a first surface and a second surface opposite to the first surface, two electrodes coupled to the coil are respectively extended out from the non-ferrite layer for connecting a module, and the first ferrite layer and the second ferrite layer are respectively arranged adjacent to the first surface and the second surface of the non-ferrite layer.