Inductive Component with Segmented Core for Low Mode Conversion

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Solution Overview

Problem

Existing data line inductors face challenges in transmitting differential signals with high data rates and low damping while effectively suppressing common-mode signals and minimizing mode conversion and ohmic losses.

Innovation Solution

The design features a compact inductive component with a core comprising two flange sections and a wire winding section, where wires are wound in a twisted manner to achieve high inductance for common-mode signals and low inductance for differential-mode signals, along with a method for producing such components using specific core materials and winding techniques to reduce leakage inductance and mode conversion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the inductive component uses a conventional core structure without flange sections, then the manufacturing process is simpler, but the wires cannot be guided through grooves to achieve symmetrical winding and low leakage inductance

Engineering Contradiction:

Improveleakage inductanceVSAvoidcore structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The core is segmented into a first core part with flange sections and a second core part, where the flange sections are separated from the main magnetic circuit. This segmentation allows the grooves to be positioned independently to guide wires symmetrically, achieving low leakage inductance while keeping the main magnetic path intact for high common-mode inductance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grooves in the flange sections act as intermediary structures that guide the wires from the contact mounts to the winding section. These grooves ensure precise wire positioning and symmetrical winding, which are critical for minimizing leakage inductance without complicating the overall core design.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the inductive component uses a compact design with integrated contact mounts, then the overall size is reduced, but the winding process becomes more complex

Engineering Contradiction:

Improvecomponent sizeVSAvoidwinding process

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The contact mounts are pre-integrated into the flange sections during core manufacturing, and the grooves are pre-formed to guide the wires. This preliminary arrangement of components simplifies the subsequent winding process by providing fixed wire paths, reducing the complexity of aligning and positioning wires during assembly.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the inductive component uses asymmetrical wire routing, then the winding process is simpler, but mode conversion increases and differential signal transmission is degraded

Engineering Contradiction:

Improvewinding processVSAvoidmode conversion

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The flange sections are positioned asymmetrically relative to the winding section, with grooves configured to guide wires in a symmetrical manner around the magnetic core. This asymmetric placement of symmetric guiding features enables both easy manufacturing and minimal mode conversion by ensuring equal wire lengths and symmetrical magnetic coupling.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The grooves in the flange sections provide localized wire guidance with specific geometric properties that ensure symmetrical wire routing. This local structural feature maintains high manufacturing ease while enforcing symmetrical wire positions critical for minimizing mode conversion and maintaining signal integrity.

Inventive Principle:

Principle #3Local quality

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 virtually undamped differential signal transmission with high damping of interference signals, low DC resistance, and reduced emission of interference radiation, making it suitable for high-speed data buses and radio-frequency applications.

Implementation Method 1

The core is produced from a ferrite material having a high magnetic permeability

Methodology Applied

Scientific EffectMagnetic permeability: Ferromagnetism

Implementation Method 2

a first wire and a second wire are wound on the core... For common-mode signals the data line inductor is intended to constitute a high inductance

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10692639B2Inductive component and method for producing an inductive component

Publication Date: 2020.06.23 TDK ELECTRONICS AG

AI summary

An inductive component and a method for producing an inductive component are disclosed. In an embodiment, the inductive component includes a first core part having wound first and second wires and a second core part arranged on the first core part. In various embodiments the inductive component has a low mode conversion, a low inductance in differential-mode operation, a high inductance for common-mode signals, a constant characteristic impedance, a low capacitive coupling of the wires, and/or a low leakage inductance.