Embedded Helical Inductor Design for Size Reduction
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Solution Overview
Problem
The miniaturization of inductors is hindered by the gap between the winding and the core, which prevents a reduction in size and thickness due to their separate components.
Innovation Solution
An inductor design featuring a first and second conductor spirally extending in a plane, stacked and joined to form a helical coil, covered by an insulation film and embedded within a magnetic body, eliminating the gap between the conductors and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the winding and core are used as separate components, then the inductor can be manufactured using conventional methods, but the gap between the winding and core prevents reduction in size and thickness
Solution Approach 1:
The patent merges the winding and core into a single integrated structure where the conductor is embedded within the magnetic body. This eliminates the gap between separate components and reduces the overall volume of the inductor, directly resolving the technical contradiction between miniaturization and structural complexity.
Solution Approach 2:
The conductor is nested within the magnetic body, with the magnetic body covering the conductor and forming an integrated unit. This nesting arrangement eliminates the need for separate mounting and reduces the gap between components, enabling size reduction while maintaining functional integrity.
2Ease of manufacture
If the winding is spaced apart from the core by a gap, then the components can be manufactured separately, but this gap hinders reduction in size
Solution Approach 1:
The patent combines the manufacturing process or assembly process to eliminate the gap between conductor and magnetic body. The conductor is embedded within the magnetic body, creating an integrated structure that reduces thickness while maintaining ease of manufacture through streamlined production methods.
3Ease of operation
If separate components are used for winding and core, then assembly is simpler, but the gap prevents miniaturization
Solution Approach 1:
The conductor is nested within the magnetic body in a integrated structure, which reduces the thickness of the inductor. The nesting arrangement simplifies the assembly process by eliminating the need to bridge gaps between separate components, while achieving miniaturization.
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 allows for a reduction in size and thickness of the inductor while improving electrical properties and facilitating easier electrical connection, enabling more compact electronic devices.
Implementation Method 1
The first conductor and the second conductor are connected to form a helical coil
Implementation Method 2
The magnetic body covers a surface of the insulation film and embeds the first conductor and the second conductor
Data Source
AI summary
An inductor includes a first conductor, a second conductor, an insulation film, and a magnetic body. The first conductor spirally extends in a plane. The second conductor spirally extends in a plane. The second conductor is stacked on and joined to the first conductor. The insulation film covers a surface of the first conductor and a surface of the second conductor. The magnetic body covers a surface of the insulation film and embeds the first conductor and the second conductor. The first conductor and the second conductor are connected to form a helical coil.