Inductor Array Component with Magnetic Blocking Layers
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Solution Overview
Problem
Inductor arrays face challenges with mutual coupling effects that increase inductance capacity and restrict miniaturization and thinness, particularly when multiple inductors are adjacent, leading to performance degradation and mounting limitations.
Innovation Solution
The inductor array component incorporates a body with multiple coil portions separated by first and second blocking layers, where the first blocking layer is formed of a dielectric material with lower permeability and the second blocking layer is ferromagnetic, reducing the coupling factor and preventing magnetic flux concentration between coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple inductors are arranged in an array to reduce mounting area and times, then productivity and space utilization are improved, but mutual coupling effects increase causing performance degradation
Solution Approach 1:
A magnetic blocking layer is introduced as an intermediary element between adjacent inductors in the array. This blocking layer, made of ferromagnetic material, acts as a mediator that redirects and confines magnetic flux, preventing it from coupling between adjacent inductors. The blocking layer thus enables close spacing of inductors for improved mounting efficiency while maintaining their electrical isolation for reliable performance.
2Volume of moving object
If inductors are placed closer together to achieve miniaturization, then device size is reduced, but mutual inductance effects increase leading to coupling problems
Solution Approach 1:
The magnetic blocking layer is strategically positioned only in the regions where magnetic flux concentration and coupling occur between adjacent inductors. This localized approach allows the inductors to be placed close together for miniaturization while the blocking layer locally redirects the magnetic flux, preventing harmful coupling effects in the critical regions between inductors.
3Reliability
If blocking layers are added between coil portions to reduce coupling factor, then mutual inductance is reduced, but device complexity increases
Solution Approach 1:
The magnetic blocking layer is integrated into the existing inductor array structure and manufactured using the same multilayer fabrication process. The blocking layer is formed as part of the magnetic body layers, combining the inductor elements and blocking structures into a single unified component. This merging approach reduces decoupling performance while avoiding the need for separate assembly steps or additional complex structures.
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 effectively decouples inductor array components, reducing the coupling factor from 6.4% to 1.5%, enhancing miniaturization and thinness while maintaining performance by absorbing magnetic flux and minimizing mutual inductance effects.
Implementation Method 1
the second blocking layer is ferromagnetic, reducing the coupling factor and preventing magnetic flux concentration between coils
Implementation Method 2
the first blocking layer is formed of a dielectric material with lower permeability
Data Source
AI summary
An inductor array component includes a body including a plurality of coil portions a coil included in the coil portions, external electrodes connected to both end portions of the coil and disposed on an outer surface of the body, a first blocking layer disposed between the coil portions, and a second blocking layer disposed within the first blocking layer.