Double-Winding Embedded Solenoid Layout for Higher Inductance Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a demand for embedded solenoid inductors with an increased inductance-to-size ratio, particularly in applications where space is limited, as existing inductors struggle to achieve high inductance while minimizing size and magnetic core material usage.
Innovation Solution
A layered process is used to construct an embedded double-winding solenoid inductor by positioning an inner winding around a magnetic core and an outer winding around the inner winding, with electrical connections through dielectric layers to generate non-opposing or opposing magnetic fields, allowing for efficient use of space and magnetic core material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a conventional single-winding solenoid inductor is used, then the structure is simple and easy to manufacture, but the inductance-to-area ratio is low and occupies more space
Solution Approach 1:
The patent implements a double-winding structure where an inner winding is positioned around a magnetic core and an outer winding is positioned around the inner winding. This nested configuration allows both windings to share the same magnetic core and occupy overlapping spatial regions, effectively doubling the inductance contribution within the same footprint area, thereby resolving the contradiction between compact area and structural complexity.
Solution Approach 2:
The patent transitions from a conventional single-layer winding to a multi-layer three-dimensional structure by stacking conducting layers separated by dielectric layers. The inner and outer windings are formed in different spatial layers, with vertical conductors connecting corresponding turns between layers. This dimensional transformation enables the inductor to achieve higher inductance density by utilizing vertical space rather than only horizontal expansion.
2Quantity of substance
If the number of windings is increased to achieve higher inductance, then the inductance value increases, but the required magnetic core material increases proportionally
Solution Approach 1:
By nesting the inner and outer windings around the same magnetic core, the patent enables both windings to contribute to inductance generation without requiring proportional increases in magnetic core material. The shared magnetic core flux path allows the combined inductance to be the sum of both windings' contributions, achieving higher inductance values while minimizing additional magnetic material usage.
3Area of moving object
If a double-winding structure is implemented, then the inductance-to-area ratio increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs a systematic layered fabrication process where conducting layers, dielectric layers, and vertical conductor structures are built sequentially in the vertical dimension. This approach transforms the complex double-winding structure into a series of manageable planar processing steps, making the manufacturing complexity controllable through standardized layer-by-layer fabrication techniques rather than attempting to wind complex three-dimensional structures directly.
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 approach results in a significant increase in the inductance-to-area ratio, reducing the required area by approximately 37% compared to conventional single-winding solenoids, while maintaining comparable inductance and reducing the need for additional magnetic core material, thus lowering costs and improving magnetic core properties.
Implementation Method 1
The inner and outer windings are electrically connected. The inner and outer windings may be connected to generate non-opposing magnetic fields in the magnetic core, or they may be connected to generate opposing magnetic fields in the magnetic core.
Data Source
AI summary
A method for constructing a solenoid inductor includes positioning an inner winding substantially around a magnetic core, positioning an outer winding substantially around the inner winding, and using a layered process to perform said positioning the inner and outer windings. The layered process includes processing a first conducting layer as a bottom layer of the outer winding, above processing a first dielectric layer, above processing a second conducting layer as a bottom layer of the inner winding, above processing a second dielectric layer, above processing a magnetic core layer, above processing a third dielectric layer, above processing a third conducting layer as a top layer of the inner winding, above processing a fourth dielectric layer, above processing a fourth conducting layer as a top layer of the outer winding, above processing a fifth dielectric layer, and the inner and outer windings are electrically connected.