Inductor Coupling Control via Encapsulant Permeability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inductors face challenges in achieving a controlled coupling coefficient while maintaining a compact size and high performance, as adjusting the number of coil turns requires changes in equipment and size, which is not efficient.
Innovation Solution
The inductor design includes a support member with through-holes and via-holes, where coil units are arranged in a bifilar configuration on one surface and spaced apart on the other, with an encapsulant having different magnetic permeability materials to control the coupling coefficient without altering the overall size or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of coil turns is changed to adjust the coupling coefficient, then the coupling coefficient can be controlled, but the equipment and size must be changed
Solution Approach 1:
The patent changes the magnetic permeability parameter of the encapsulant material to control the coupling coefficient. By selecting encapsulants with different magnetic permeability values, the coupling coefficient can be adjusted within a range of 0.1 to 0.9 without changing the coil structure or equipment
Solution Approach 2:
The encapsulant acts as an intermediary element between the coil units. By modifying the magnetic properties of this intermediary material, the magnetic coupling between coils is controlled, achieving coupling coefficient adjustment without direct modification of the coils themselves
2Adaptability or versatility
If the number of coil turns is changed to adjust the coupling coefficient, then the coupling coefficient can be controlled, but the size must be changed
Solution Approach 1:
The patent maintains a fixed inductor size while achieving coupling coefficient control by changing only the magnetic permeability parameter of the encapsulant material. This allows the same physical device to provide different coupling coefficients through material selection rather than structural modification
3Area of stationary object
If various arrays with reduced mounting areas are used, then miniaturization is achieved, but the coupling coefficient control becomes difficult
Solution Approach 1:
The patent maintains a compact mounting area while achieving coupling coefficient control through parameter changes in the encapsulant material. The magnetic permeability of the encapsulant serves as a control parameter that does not require additional space or complex arrangements
Solution Approach 2:
The encapsulant material serves as a space-efficient intermediary that provides coupling control functionality without requiring additional mounting area. The same encapsulated structure serves both miniaturization and coupling control functions
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 allows for the fine-tuning of the coupling coefficient within a range of 0.1 to 0.9 by varying the magnetic permeability of the encapsulant, enhancing the inductor's performance without changing the size or configuration of the coil units.
Implementation Method 1
The encapsulant includes a first encapsulant and a second encapsulant, and magnetic permeability of the first encapsulant different from magnetic permeability of the second encapsulant
Data Source
AI summary
An inductor includes a body including a support member having a first through-hole, a second through-hole, a first via-hole and a second via-hole, the first and second via-holes being spaced apart from the first and second through-holes, a first coil unit and a second coil unit disposed on one surface of the support member, a third coil unit and a fourth coil unit facing the one surface of the support member, and an encapsulant encapsulating the support member and the first to fourth coil units and including a magnetic material, and a first external electrode to a fourth external electrode respectively connected to the first to fourth coil units on an external surface of the body. The encapsulant includes a first encapsulant and a second encapsulant having magnetic permeability different from each other.