Inductor with Columnar Core and Multi-Stage Coil for High Inductance
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Solution Overview
Problem
Inductors used in electronic devices face a challenge in achieving high inductance values while being compact in size, as the extended portions and outer electrodes occupy significant space, limiting the coil's size and performance.
Innovation Solution
The inductor design includes a magnetic base with a columnar portion and a coil with wound and extended portions, where the coil is wound around the columnar portion with flat surface portions facing each other, and a magnetic outer coating containing magnetic powder, allowing for improved inductance values within spatial constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the extended portion and outer electrode are connected in the body, then the inductor structure is stable, but the region occupied by the coil is limited
Solution Approach 1:
The coil is configured to wind around the columnar portion in a multi-stage manner, utilizing vertical stacking (upper stage and lower stage) to increase the effective coil area without expanding the horizontal footprint. This dimensional transition allows the coil to occupy more space in the vertical direction while maintaining a compact horizontal profile.
Solution Approach 2:
The coil's extended portions are embedded within the body structure, with the upper stage portion containing an inner peripheral portion that connects to the lower stage portion. This nested configuration allows the coil windings to be compactly arranged around the columnar portion, maximizing the use of available space.
2Reliability
If the coil size is increased to obtain high inductance value, then the inductance performance is improved, but the inductor size increases
Solution Approach 1:
The inductor utilizes a multi-stage vertical configuration with the coil winding around the columnar portion at different heights. The upper stage portion and lower stage portion are stacked vertically, allowing the inductance to be increased by adding more winding layers in the vertical dimension rather than expanding horizontally.
Solution Approach 2:
The magnetic base includes a columnar portion with specific geometric characteristics that concentrate magnetic flux in the coil region. The magnetic outer coating is applied selectively to cover specific surfaces, enhancing magnetic properties locally where needed while keeping the overall structure compact.
3Reliability
If the coil is wound with flat surface portions facing each other, then the inductance value is improved, but the manufacturing complexity increases
Solution Approach 1:
The coil is divided into distinct segments: the upper stage portion, the lower stage portion, and the inner peripheral portion connecting them. Each segment can be independently formed and positioned around the columnar portion, simplifying the manufacturing process while achieving the desired flat surface configuration for high inductance.
Solution Approach 2:
The columnar portion is pre-formed on the magnetic base before the coil is wound around it. This preliminary structure provides a stable foundation and guide for the coil winding process, ensuring proper alignment of the flat surface portions and reducing manufacturing complexity.
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 enhances the inductance value and maintains performance even with spatial limitations, allowing for a higher rated current and improved coil dimensions, while reducing the inductor's size.
Implementation Method 1
The body includes a magnetic base, a coil, and a magnetic outer coating. The magnetic base includes a base portion and a columnar portion formed on an upper surface of the base portion. The coil includes a wound portion and a pair of extended portions.
Data Source
AI summary
An inductor includes a body having a substantially rectangular parallelepiped shape and a pair of outer electrodes. The body includes a core having a base and a columnar portion formed on an upper surface of the base, includes a coil including a pair of extended portions and a wound portion having an upper stage portion and a lower stage portion, and includes a magnetic material containing magnetic powder and covering a part of the core, a part of the pair of extended portions, and the wound portion. The pair of outer electrodes are disposed on a mounting surface of the body and are connected to the pair of respective extended portions. A shape in plan view of the wound portion is hollow and a substantially circular shape having a short direction and a long direction, and the upper stage portion includes a protruding portion protruding in the short direction.