Inductor With Tapered Coil Patterns To Mitigate Magnetic Flux Neck
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Solution Overview
Problem
The miniaturization of inductors leads to a concentration of magnetic flux, resulting in a magnetic flux neck at the periphery of the core, which affects the inductance and DC-bias characteristics.
Innovation Solution
The inductor design features a body with a support member and coil portion where the maximum thickness of each coil pattern increases toward the outer portion, with a wider lower surface line width and narrower upper surface line width, and includes a sealing portion with magnetic materials to optimize magnetic flux flow, reducing magnetic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inductor is miniaturized to reduce size, then the device dimensions are reduced, but magnetic flux concentrates in the core region causing increased magnetic resistance and degraded inductance characteristics
Solution Approach 1:
The coil pattern is designed with non-uniform thickness where the maximum thickness increases toward the outer portion of the body. Specifically, the lower surface line width is wider than the upper surface line width, creating a tapered structure. This local variation in thickness optimizes the magnetic flux distribution in different regions, preventing concentration at the core periphery while maintaining compact overall dimensions.
Solution Approach 2:
The patent changes the geometric parameters of the coil pattern by varying the maximum thickness across different locations. The thickness parameter is not kept constant but is instead optimized to increase toward the outer portion, which alters the magnetic flux flow path and reduces magnetic resistance in the core region, thereby improving inductance characteristics despite miniaturization.
2Ease of manufacture
If the coil pattern has uniform thickness to simplify manufacturing, then the manufacturing process is easier, but magnetic flux flow is optimized poorly leading to increased magnetic resistance
Solution Approach 1:
Rather than using uniform thickness throughout, the patent applies local quality by making the maximum thickness of the coil pattern increase toward the outer portion of the body. The lower surface line width is specifically designed to be wider than the upper surface line width, creating a tapered structure that optimizes magnetic flux flow locally in different regions while remaining manufacturable through standard PCB or laminated construction techniques.
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 enhances the effective cross-sectional area for magnetic flux flow, mitigating the magnetic flux neck and improving inductance and DC-bias characteristics, while maintaining a compact size.
Implementation Method 1
Since magnetic flux concentrates mainly in the core region inside the coil, the flow of the magnetic flux must be optimized by improving the construction technology for the concentrated region of the magnetic flux
Implementation Method 2
The coil portion includes first and second coils on opposing surfaces of the support member, respectively
Data Source
AI summary
An inductor comprises a body and external electrodes arranged on an external surface of the body. The body includes a support member, a coil portion supported by the support member, and a sealing portion sealing the support member and the coil portion. The coil portion includes a plurality of coil patterns. A maximum thickness of each coil pattern in the plurality of coil patterns increases toward an outer portion of the body, and a line width of a lower surface in the coil patterns is wider than a line width of an upper surface.