Inductor Array Layout for Low Magnetic Coupling in Tight Spacing
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Solution Overview
Problem
Conventional inductor arrays face challenges in reducing magnetic coupling between internal conductors when they are arranged closer together, which affects the desired characteristics of each inductor.
Innovation Solution
The inductor array design includes a magnetic base body with internal conductors spaced apart such that the distance between them is less than twice the distance from the conductors to the surfaces of the magnetic base body, with specific aspect ratios and overlapping inter-conductor regions to minimize magnetic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the distance between internal conductors is reduced to increase self-inductance efficiently, then the self-inductance increases, but the magnetic coupling between inductors increases unfavorably
Solution Approach 1:
The patent introduces a third dimension (depth direction perpendicular to the substrate) by providing magnetic bases with different thicknesses. The first magnetic base has a greater thickness than the second magnetic base, creating a vertical dimensional difference that allows the internal conductors to be positioned at different depths. This dimensional change enables the conductors to be closer horizontally (improving self-inductance) while maintaining adequate magnetic isolation through the thickness difference (reducing magnetic coupling).
Solution Approach 2:
The patent employs asymmetric design by making the first magnetic base have a greater thickness than the second magnetic base. This asymmetric thickness configuration creates an uneven magnetic path length and magnetic reluctance between the two inductors, which helps to reduce the magnetic coupling coefficient while allowing the internal conductors to be positioned closer together for improved self-inductance.
2Object-generated harmful factors
If the distance between internal conductors is set to three or more times the distance from conductors to magnetic base body surfaces, then magnetic coupling is reduced, but the mounting space requirement increases
Solution Approach 1:
By utilizing the vertical dimension through different magnetic base thicknesses, the patent reduces the required horizontal spacing between internal conductors. The thickness difference in the vertical direction provides additional magnetic isolation, allowing the conductors to be positioned closer in the horizontal plane, thereby reducing the overall mounting space while maintaining low magnetic coupling.
Solution Approach 2:
The patent changes the geometric parameters of the magnetic bases, specifically the thickness parameter, to optimize the balance between magnetic coupling and self-inductance. By setting the first magnetic base thickness to be greater than the second, the patent achieves a coupling coefficient of 0.2 or less while reducing the horizontal distance between conductors, thus minimizing mounting space requirements.
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 reduces magnetic coupling between inductors to less than 0.2, allowing each inductor to function independently and suitable for high-current circuits like DC-to-DC converters, with improved self-inductance and energy density.
Implementation Method 1
When the magnetic base body surrounds the internal conductors with even thicknesses, the self-inductance of the inductors can be efficiently increased
Implementation Method 2
the magnetic base body includes an inter-conductor region disposed between the first internal conductor and the second internal conductor and overlapping with both the first internal conductor and the second internal conductor as viewed from a reference axis direction
Data Source
AI summary
An inductor array of the invention includes a magnetic base body, a first internal conductor within the base body, and a second internal conductor adjacent to the first internal conductor. The first and second internal conductors are arranged along a reference axis. The base body includes an inter-conductor region between the first and second internal conductors. The inter-conductor region has a first section cut along a reference plane including the reference axis, and a first reference axis direction dimension of the first section in the reference axis direction may be less than double a shortest distance between the first internal conductor and a surface of the base body in the reference plane. A first aspect ratio of the first section, which is a ratio of a first orthogonal direction dimension in a direction orthogonal to the reference axis to the first reference axis direction dimension, may be less than 1.