Inductor Conductor with Stacked Insertion Sub-Parts
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Solution Overview
Problem
The existing inductors have a high DC resistance in their conductor members, which is a limitation that needs to be reduced for improved performance.
Innovation Solution
The inductor configuration includes a conductor member with an insertion part composed of stacked sub-parts, where the sum of their thicknesses exceeds the thicknesses of the outer surface arrangement parts, and the conductor member is inserted into a magnetic core with specific terminal and boundary parts, allowing for reduced DC resistance while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of the conductor member is increased to reduce DC resistance, then the DC resistance decreases, but the size of the insertion part increases
Solution Approach 1:
The conductor member transitions from a single-layer structure to a multi-layer stacked structure, utilizing the vertical dimension (thickness direction) to increase the effective conduction path area without increasing the horizontal footprint. This allows DC resistance reduction while maintaining compact insertion part dimensions.
Solution Approach 2:
The conductor member is divided into multiple sub-conductor members that are stacked in the thickness direction. Each sub-conductor member has a thickness smaller than the outer surface arrangement part thickness, but their combined thickness exceeds the outer surface arrangement part thickness, creating multiple parallel conduction paths that reduce overall DC resistance.
2Volume of moving object
If the conductor member is made thinner to reduce insertion part size, then the insertion part size decreases, but the DC resistance increases
Solution Approach 1:
Instead of reducing conductor thickness in the horizontal plane, the solution stacks multiple thin conductor layers in the vertical thickness direction. This maintains a compact insertion part size while increasing the effective conduction area through multi-layer configuration, thereby reducing DC resistance.
Solution Approach 2:
The conductor member is constructed as a composite structure of multiple sub-conductor members stacked together. This composite configuration combines the advantages of thin individual layers (compact size) with the benefits of multiple layers in parallel (reduced resistance), achieving both size reduction and resistance reduction simultaneously.
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 configuration effectively reduces the DC resistance of the conductor member, allowing for improved performance without increasing the size of the insertion part, and enables easy setting of the desired resistance value.
Implementation Method 1
The insertion part includes an insertion first sub part and an insertion second sub part that is stacked on the insertion first sub part. A sum of the thicknesses of the insertion first and second sub parts is larger than each of a thickness of the first outer surface arrangement part and a thickness of the second outer surface arrangement part.
Data Source
AI summary
An inductor includes a magnetic core and a conductor member. The conductor member is configured with: an insertion part that is inserted into the magnetic core; first and second outer surface arrangement parts that are directly or indirectly connected to ends of the insertion part and are arranged along first and second outer surfaces of the magnetic core, respectively; and first and second terminal parts that are connected to the first and second outer surface arrangement parts, respectively. The insertion part includes an insertion first sub part and an insertion second sub part that is stacked on the insertion first sub part. A sum of the thicknesses of the insertion first and second sub parts is larger than a thickness of the first outer surface arrangement part and larger than a thickness of the second outer surface arrangement part.