Embedded Inductor in Magnetic Material for Thin Profile
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Solution Overview
Problem
The challenge is to create a thin inductor for small-size electronic products, as traditional helical inductors with magnetic cores occupy significant space, hindering size reduction in electronic devices.
Innovation Solution
An inductor is fabricated using a magnetic material with embedded conductive lines and electrodes, where the conductive lines are patterned on a metal plate, embedded in a magnetic material containing magnetic powder and insulating resin, and specific electrodes are exposed to enhance adhesion and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a helical inductor with a magnetic core is used, then inductance is achieved, but the inductor occupies significant space and cannot be made thin
Solution Approach 1:
The patent transitions from a three-dimensional helical coil structure to a two-dimensional planar conductor pattern embedded in a magnetic material layer. This dimensional change allows the inductor to achieve its function in a thin profile while maintaining inductance through the magnetic material's properties and the conductor's geometric design.
Solution Approach 2:
The patent uses a composite structure combining a magnetic material (containing magnetic powder and insulating resin) with an embedded conductive line. This composite approach enables the inductor to achieve both magnetic flux concentration for inductance and electrical conduction in a thin, integrated structure that would not be possible with single materials.
2Area of stationary object
If the magnetic core three-dimensionally occupies space, then magnetic flux is contained, but the overall device size increases
Solution Approach 1:
The patent extracts the magnetic core from its traditional three-dimensional helical configuration and transforms it into a thin, planar magnetic material layer. This extraction and reconfiguration maintains the essential function of magnetic flux containment while dramatically reducing the vertical space occupation and overall device footprint.
Solution Approach 2:
The magnetic material is arranged in a planar configuration rather than a three-dimensional core structure, shifting the magnetic flux containment from vertical to lateral dimensions. This allows the inductor to maintain effective magnetic coupling while achieving a thin profile suitable for compact electronic devices.
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 allows for a thinner inductor design, reducing the overall size of electronic devices while maintaining inductance and reliability, and enabling efficient power supply to components like CPUs.
Implementation Method 1
a magnetic material containing a magnetic powder and an insulating resin
Implementation Method 2
a magnetic material containing a magnetic powder and an insulating resin
Implementation Method 3
a conductive line embedded in the magnetic material... connected to one end of the conductive line, and a second electrode partially exposed from the magnetic material and connected to another end of the conductive line
Data Source
AI summary
An inductor includes a magnetic material containing a magnetic powder and an insulating resin, a conductive line embedded in the magnetic material, a first electrode partially exposed from the magnetic material and connected to one end of the conductive line, and a second electrode partially exposed from the magnetic material and connected to another end of the conductive line.