Inductor Non-Magnetic Layer Width Variation Reduces AC Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductors with magnetic and non-magnetic materials experience high alternating current resistance due to magnetic saturation caused by concentrated magnetic field lines around coil corners.
Innovation Solution
An inductor design featuring a helical coil with an inner circumferential surface covered by a non-magnetic material, where the width of the non-magnetic material in the center portion is greater than at the end portions, widening the magnetic field line interval and reducing saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coil is built into a multilayer body with magnetic material, then inductance is achieved, but magnetic saturation occurs at coil corners causing high alternating current resistance
Solution Approach 1:
The patent applies local quality by making the non-magnetic material layer thickness position-dependent: thicker at end portions (where magnetic saturation occurs) and thinner at center portions. This localized variation in material property directly addresses the magnetic saturation problem at coil corners while maintaining inductance performance.
Solution Approach 2:
The patent introduces asymmetry in the non-magnetic material layer configuration, where the layer thickness differs between end portions and center portions of the coil. This asymmetric design creates wider magnetic field line intervals at problematic end portions, suppressing magnetic saturation without compromising the overall inductor function.
2Object-affected harmful factors
If non-magnetic material covers the inner circumferential surface of the coil, then magnetic saturation is suppressed, but alternating current resistance increases due to magnetic field line concentration at end portions
Solution Approach 1:
The patent resolves this contradiction by applying local quality through position-dependent non-magnetic material thickness. The thicker coverage at end portions suppresses magnetic saturation locally where it occurs, while the thinner coverage at center portions maintains appropriate magnetic field characteristics, achieving both goals simultaneously.
Solution Approach 2:
The patent employs parameter changes by varying the thickness parameter of the non-magnetic material layer along the coil length. This continuous parameter variation optimizes the balance between suppressing magnetic saturation at end portions and maintaining proper magnetic field distribution throughout the coil, thereby reducing alternating current resistance.
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 effectively suppresses magnetic saturation and reduces alternating current resistance in inductors with magnetic and non-magnetic materials.
Implementation Method 1
magnetic saturation is liable to occur. As a result, a problem occurs in that the alternating current resistance is high
Implementation Method 2
lines of magnetic force are concentrated around corners of the coil conductors located in end portions of the coil
Data Source
AI summary
An inductor includes a multilayer body, which is composed of a non-magnetic material and a magnetic material, and a coil. An inner circumferential surface of the coil is covered by non-magnetic material layers. The sum of the width of a coil conductor forming part of the coil and the width of a non-magnetic material layer covering an inner circumferential side of the coil conductor that are located in a center portion of the coil in a z-axis direction is larger than the sum of the width of a coil conductor forming part of the coil and the width of a non-magnetic material layer covering the coil conductor that are located in an end portion of the coil on the positive side in the z-axis direction.