Inductor with Segmented Magnetic Core for DC-DC Converter

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Solution Overview

Problem

The manufacturing costs of inductors with composite magnetic cores are increased due to the need for a structure to wind conductors around the magnetic core, which is complex and costly.

Innovation Solution

The inductor design eliminates the need for a conductor winding structure by laminating inductor conductor layers and a magnetic core layer with different magnetic substances, using via conductors to connect them, thereby reducing manufacturing complexity and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a structure for winding a conductor around a composite magnetic core is used, then the inductor achieves desired direct-current superposition characteristics, but the manufacturing cost increases

Engineering Contradiction:

Improvedirect-current superposition characteristicsVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The inductor is divided into multiple layers including first and second inductor conductor layers and a magnetic core layer disposed between them. This segmentation eliminates the need for winding conductors around the magnetic core, as the conductor layers are formed as separate planar structures that can be manufactured using standard PCB techniques, thereby reducing manufacturing complexity and cost while maintaining the desired direct-current superposition characteristics through the layered configuration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a three-dimensional winding structure to a two-dimensional layered structure. Instead of winding conductors around the magnetic core in 3D space, the conductor layers are formed as flat planar structures on either side of the magnetic core layer, with via conductors providing vertical connections. This dimensional change simplifies manufacturing while achieving the same electrical functionality

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If a composite magnetic core with multiple magnetic substances is used, then the inductance can be adjusted for different DC current regions, but the device complexity increases

Engineering Contradiction:

Improveinductance adjustment capabilityVSAvoidmagnetic core structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The magnetic core is segmented into multiple magnetic substance portions, each with different magnetic properties, disposed in specific regions within the magnetic core layer. This segmentation allows different portions of the magnetic core to contribute differently to the inductance based on the DC current level, enabling inductance adjustment capability while maintaining a relatively simple overall structure that can be manufactured using standard PCB lamination processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the magnetic core are assigned different magnetic substances with specific properties tailored to their functional requirements. The first and second magnetic substance portions have different magnetic properties that enable the inductor to exhibit high inductance at low DC currents and maintain stable inductance at high DC currents, achieving adaptability through localized material properties rather than complex overall structure

Inventive Principle:

Principle #3Local quality

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 maintains desired direct-current superposition characteristics while reducing manufacturing costs and allowing for adjustable direct-current superposition characteristics through varying magnetic substance proportions or types, enhancing power conversion efficiency and preventing output short circuits.

Implementation Method 1

The magnetic core layer includes a first magnetic substance portion including a first magnetic substance, and a second magnetic substance portion including a second magnetic substance. Magnetic properties of the second magnetic substance are different from magnetic properties of the first magnetic substance.

Methodology Applied

Scientific EffectMagnetic properties of magnetic substances: Magnetism

Implementation Method 2

The first and second via conductors are connected to the first and second inductor conductor layers. The first and second terminals are electrically connected through the first and second via conductors.

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10714252B2Inductor and DC-DC converter

Publication Date: 2020.07.14 MURATA MFG CO LTD

AI summary

An inductor includes a first terminal and a second terminal, a first inductor conductor layer and a second inductor conductor layer, a magnetic core layer, and via conductors. The magnetic core layer is disposed between the first and second inductor conductor layers. The via conductors are connected to the first and second inductor conductor layers. The first and second terminals are electrically connected through the via conductors. The magnetic core layer includes a first magnetic substance portion including a first magnetic substance, and a second magnetic substance portion including a second magnetic substance. Magnetic properties of the second magnetic substance are different from magnetic properties of the first magnetic substance.