Horizontal Core Inductor for Compact High Power
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Solution Overview
Problem
The challenge is to create smaller and more powerful inductors that fit within the limited space of modern electronic devices while maintaining or improving performance, as traditional inductors often require increased footprint and height with enhanced induction and power handling capabilities.
Innovation Solution
The design features a core with a conductor wound around it, oriented horizontally to minimize height and allow for longer core lengths, enabling more turns and higher power handling without increasing the component's height, along with terminals formed by the conductor ends for mounting and electrical coupling, and an outer body that covers the core and conductor to enhance magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the induction and power handling of an inductor is increased, then the performance is improved, but the footprint and height of the inductor increase
Solution Approach 1:
The patent reorients the core from a vertical configuration to a horizontal configuration, extending the core in the lateral dimension rather than the vertical dimension. This allows the magnetic path length to increase (improving power handling) while keeping the height constraint satisfied. The core extends horizontally with the conductor wound around it, transforming the growth direction from vertical to horizontal.
2Power
If the induction and power handling of an inductor is increased, then the performance is improved, but the height of the inductor increases
Solution Approach 1:
The patent reorients the core from a vertical configuration to a horizontal configuration, extending the core in the lateral dimension rather than the vertical dimension. This allows the magnetic path length to increase (improving power handling) while keeping the height constraint satisfied. The core extends horizontally with the conductor wound around it, transforming the growth direction from vertical to horizontal.
3Device complexity
If a traditional vertical core configuration is used, then the structure is simple, but the height increases and space is wasted
Solution Approach 1:
The patent inverts the traditional vertical core configuration by orienting the core horizontally. Instead of extending the core upward, it extends the core laterally along the substrate. This inversion maintains structural simplicity while eliminating the height problem, allowing the core to achieve the required magnetic path length without increasing the vertical dimension.
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 allows for a more compact and powerful inductor with improved inductance and current handling capabilities, suitable for high-power applications while maintaining a reduced footprint, effectively addressing the space constraints in portable electronic devices.
Implementation Method 1
a core with a conductor wound around it, oriented horizontally to minimize height and allow for longer core lengths, enabling more turns and higher power handling
Data Source
AI summary
An electronic component, such as, for example, an inductor, includes a core defining an axis and a conductor that is at least partially wound about the core. The electronic component further includes a mounting surface defining a plane that extends substantially parallel to the axis of the core. The mounting surface is configured to engage a surface of a board. The conductor may include a first terminal and a second terminal extending along the plane such that the first and second terminals are able to be mounted to the surface of the board.