Integrated Inductor with Seamless Ferromagnetic Core
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Solution Overview
Problem
Conventional discrete ferrite inductors are limited in miniaturization due to size and cost constraints in electronic applications, particularly in mobile devices, and have limitations in integration with other passive or active devices.
Innovation Solution
An integrated inductor design featuring a substrate with a conductor and a seamless ferromagnetic material surrounding at least a portion of the conductor, where the magnetic material is applied by molding or other methods to form a closed magnetic loop, allowing for higher inductance values and integration with other components on the same substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete ferrite inductors are used in standard rectangular packages, then inductance function is provided, but device size and cost increase
Solution Approach 1:
The patent combines the inductor and capacitor into a single integrated device structure. The ferromagnetic core is formed as an integrated structure with conductive traces arranged to provide both inductive and capacitive functions within the same physical component, eliminating the need for separate discrete inductor and capacitor components.
Solution Approach 2:
The patent transitions from planar two-dimensional conductor traces to a three-dimensional structure by forming conductive traces that extend vertically between upper and lower surfaces of the ferromagnetic core, utilizing the third dimension to increase inductance density and reduce the footprint area.
2Reliability
If discrete ferrite inductors are used, then inductance function is provided, but integration with other components is limited
Solution Approach 1:
The patent merges multiple passive components (inductor and capacitor) into a single integrated device, enabling direct integration with other circuit elements without requiring separate discrete components or complex interconnections.
Solution Approach 2:
The integrated inductor structure provides multiple functions within a single component, including inductance, capacitance, and magnetic shielding, making it a universal component that can replace multiple discrete components in various circuit applications.
3Reliability
If layered ferrite approach with multiple conductive layers is used, then higher inductance is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the conductive path into multiple sections with different geometries (straight sections, curved sections, overlapping sections) within a single continuous trace structure, allowing independent optimization of each segment's contribution to inductance while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies local quality by varying the trace geometry, width, and spacing in different regions of the inductor to optimize magnetic flux distribution and inductance density in specific areas, achieving high inductance values through localized design features rather than uniform complexity throughout.
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 achieves higher inductance values at lower series resistance, supports cost-effective fabrication, and enables compact integration with other components, addressing the size and cost limitations of conventional discrete inductors.
Implementation Method 1
a seamless ferromagnetic material surrounding at least a first portion of the conductor
Implementation Method 2
form a closed magnetic loop
Implementation Method 3
conductor disposed above the substrate and a seamless ferromagnetic material surrounding at least a first portion of the conductor
Data Source
AI summary
In one embodiment, an inductor has a substrate, a conductor disposed above the substrate and a seamless ferromagnetic material surrounding at least a first portion of the conductor.