Dual-Core Coil Component for High Current Ripple Reduction
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Solution Overview
Problem
There is a need for highly efficient small and thin power inductors capable of operating at high current levels with reduced mounting area requirements, particularly in electronic devices, while maintaining a balance between coupling and leakage inductance to minimize current ripples and improve efficiency.
Innovation Solution
A coil component with a magnetic body having two cores, where first and second coil parts are disposed on one surface and third and fourth coil parts on the other surface, connected by a penetration part through the cores, and external electrodes for connection, forming a structure that enhances coupling coefficient and leakage inductance without increasing the mounting area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coupled inductor structure is used to increase coupling coefficient and mutual inductance, then inductor current ripples are reduced, but the device complexity increases
Solution Approach 1:
The patent combines multiple coil parts (first, second, third, and fourth coil parts) into a single integrated magnetic body with a shared magnetic core. This merging approach achieves coupled inductor functionality with increased mutual inductance while maintaining a compact, unified structure rather than using separate inductors, thereby reducing device complexity compared to traditional coupled inductor designs.
Solution Approach 2:
The patent utilizes a three-dimensional magnetic core structure where coil parts are wound around different portions of the same magnetic body. This spatial arrangement in multiple dimensions creates magnetic coupling between coils without requiring complex planar layouts, achieving high coupling coefficients while maintaining simple manufacturing processes.
2Area of stationary object
If the size of mounting area is reduced for miniaturization, then product thickness and area are decreased, but it becomes difficult to maintain high coupling coefficient and appropriate leakage inductance
Solution Approach 1:
The patent employs a nested structure where multiple coil parts are integrated within a single magnetic body. The first and second coil parts are wound around one portion of the magnetic core, while the third and fourth coil parts are wound around another portion, creating a compact nested arrangement that achieves high coupling coefficients without increasing mounting area.
Solution Approach 2:
The patent optimizes the magnetic core geometry and coil winding parameters to achieve the desired coupling coefficient and leakage inductance values within a reduced mounting area. By carefully controlling the magnetic path length, core cross-sectional area, and winding configurations, the design maintains appropriate electrical parameters despite the reduced physical size.
3Ease of manufacture
If non-coupled inductor form is used, then manufacturing is simpler, but inductor current ripples increase and efficiency decreases
Solution Approach 1:
The patent merges multiple coil parts into a single integrated magnetic body structure, achieving coupled inductor functionality that reduces current ripples and improves efficiency. This unified structure maintains manufacturing simplicity by using a single magnetic core and standardized winding processes, avoiding the need for complex assembly of separate inductor components.
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 increases the coupling coefficient and mutual inductance, reducing output and inductor current ripples, thereby enhancing the efficiency of the inductor array chip without expanding the mounting area, as demonstrated by the comparison with non-coupled inductor examples.
Implementation Method 1
a connection part disposed to penetrate through two cores in the magnetic body and connecting the two cores to each other
Implementation Method 2
first and second coil parts disposed on one surface of the substrate, and third and fourth coil parts disposed on the other surface of the substrate
Data Source
AI summary
There are provided a coil component and a board having the same. The coil component may include: a magnetic body including a substrate having two cores, first and second coil parts disposed on one surface of the substrate, and third and fourth coil parts disposed on the other surface of the substrate; a connection part disposed to penetrate through the two cores in the magnetic body and connecting the two cores to each other; and first to fourth external electrodes disposed on outer surfaces of the magnetic body and connected to the first to fourth coil parts.