Shielded Inductor Assembly for Compact Magnetic Field Containment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inductors face challenges with inefficient and cumbersome magnetic shielding, which interferes with other electronic components and takes up valuable space, necessitating a more effective and space-efficient shielding solution.
Innovation Solution
A shielded inductor design featuring a core body with a conductive shield covering its outer surface, utilizing an insulating material between the core and shield, and extensions like lip portions, side covers, and tabs to secure the shield, manufactured through pressure molding and stamping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If large electromagnetic shielding is used to cover the inductor, then electromagnetic interference is reduced, but space is consumed and the device becomes cumbersome
Solution Approach 1:
The shield is integrated directly with the inductor body to form a single compact unit, merging the shielding function with the inductor structure itself. This eliminates the need for separate large shielding components and reduces overall space consumption while maintaining electromagnetic interference protection.
Solution Approach 2:
The shield is nested within or around the inductor core structure, with the shielding material positioned in close proximity to the magnetic core. This nested arrangement allows the shield to effectively contain electromagnetic fields within a minimal external footprint, reducing the overall device area.
2Object-affected harmful factors
If traditional shielding methods are used, then electromagnetic radiation is blocked, but the shielding becomes difficult to manufacture and assemble
Solution Approach 1:
The shield is combined with the inductor core as an integrated structure, allowing both components to be manufactured together in a single process. This integration eliminates separate assembly steps and simplifies manufacturing while maintaining effective electromagnetic radiation shielding.
Solution Approach 2:
The shielding material is applied as a coating or layer with optimized thickness and material properties that can be directly formed during the inductor manufacturing process. This approach changes the shielding from a separate mechanical assembly to a process-integrated feature, greatly simplifying manufacturing.
3Object-affected harmful factors
If the shield covers the entire core body, then electromagnetic shielding is maximized, but the inductor body space is reduced
Solution Approach 1:
The shield is applied selectively to specific surfaces or regions of the inductor core where electromagnetic radiation is most significant. This localized shielding approach provides adequate protection against electromagnetic interference while preserving maximum inductor body volume for the magnetic core and windings.
Solution Approach 2:
Rather than providing complete 360-degree shielding, the shield covers only the critical surfaces that contribute most to electromagnetic interference. This partial shielding approach achieves sufficient protection while minimizing the volume consumed by the shielding material.
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
The solution effectively reduces electromagnetic interference, minimizes space usage, and enhances the inductor's performance by providing a simpler and cost-effective shielding mechanism, with a significant reduction in magnetic radiation field strength and increased operating voltage.
Implementation Method 1
When the current flowing through an inductor changes, the time-varying magnetic field induces a voltage in the conductor, according to Faraday's law of electromagnetic induction
Implementation Method 2
The shield provides protection from electromagnetic fields by reducing the exposed portions of the core body
Data Source
Figure 1A~1F
Figure 1G~1I
Figure 2A~2D
AI summary
A shielded inductor and a method of making a shielded inductor are provided. The shielded inductor includes a core body surrounding a conductive coil, leads in electrical communication with the coil, and a shield covering at least parts of the outer surface of the core body. An insulating material may be provided between parts of the core body and parts of the shield. A method of making a shielded inductor is also provided.