Embedded PCB Inductor Core Layout for Lower Eddy Current Loss
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Solution Overview
Problem
Inductors in electronic circuits suffer from significant eddy current losses and efficiency reduction due to excessive heating, which is exacerbated by the miniaturization trend in electronic devices, necessitating improved power management solutions.
Innovation Solution
A circuit board integrated inductor design featuring a magnetic core embedded within the circuit board, with a coil partially or fully embedded and a grid-patterned magnetic layer configuration to minimize eddy current losses and enhance inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional inductor is used in electronic circuits, then the inductor can perform current limiting and filtering functions, but the inductor generates significant eddy current losses and excessive heating
Solution Approach 1:
The magnetic core is divided into multiple magnetic layers stacked in the thickness direction, with insulating layers between them. This segmentation breaks the continuous magnetic path into discrete segments, interrupting eddy current loops and reducing eddy current losses while maintaining the magnetic core's overall functionality for current limiting and filtering operations
Solution Approach 2:
Insulating layers are introduced between the magnetic layers to act as intermediaries that block eddy current paths. These insulating layers prevent direct electrical contact between adjacent magnetic layers, thereby reducing eddy current losses without compromising the magnetic coupling necessary for inductor operation
2Volume of moving object
If inductors are miniaturized to reduce device footprint, then the overall size of electronic devices can be reduced, but eddy current losses increase and efficiency decreases
Solution Approach 1:
The inductor design transitions from a planar structure to a three-dimensional stacked structure with magnetic layers arranged in the thickness direction. This vertical stacking enables compact footprint while the insulating layers between stacks prevent eddy current losses, achieving miniaturization without sacrificing efficiency
Solution Approach 2:
The inductor employs a composite structure combining magnetic layers with insulating layers in a stacked configuration. This composite design integrates both magnetic functionality and eddy current suppression within a compact volume, enabling miniaturized inductors to maintain low loss characteristics
3Area of stationary object
If the magnetic core is embedded in the circuit board with a grid-patterned magnetic layer, then inductance is optimized and footprint is reduced, but manufacturing complexity increases
Solution Approach 1:
The magnetic core is segmented into multiple layers with a grid-patterned arrangement of magnetic sub-members in the first magnetic layer. This segmentation achieves optimized inductance distribution and compact footprint while the modular stacked structure facilitates systematic manufacturing despite the complex pattern
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
The design reduces eddy current losses, improves efficiency, and allows for miniaturization of electronic devices by optimizing inductance and reducing the overall footprint of inductors.
Implementation Method 1
In electronic circuits, an inductor may limit current flow of an alternating current
Implementation Method 2
The inductor in the art may have a large eddy current loss... The magnetic core includes a first magnetic layer and a second magnetic layer insulated from the first magnetic layer; the first magnetic layer includes a plurality of magnetic sub-members... spaced apart from each other
Data Source
AI summary
A circuit board integrated inductor includes: a circuit board; and an inductor, including a magnetic core and a coil. The magnetic core is embedded in the circuit board, and the coil is at least partially embedded in the circuit board and surrounds an outer periphery of the magnetic core. The magnetic core includes a first magnetic layer and a second magnetic layer insulated from the first magnetic layer; the first magnetic layer includes a plurality of magnetic sub-members, each of the plurality of magnetic sub-members extends along a first direction, and the plurality of magnetic sub-members are spaced apart from each other along a second direction and arranged on a surface of the second magnetic layer, wherein the first direction intersects the second direction.