Laminate Inductor With Magnetic Gap Layers For Saturation Control
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Solution Overview
Problem
Conventional laminated inductors experience significant variations in inductance and poor DC-superimposed characteristics due to magnetic saturation at large magnetization currents, limiting their operational effectiveness in high-frequency applications.
Innovation Solution
The laminate device incorporates multiple magnetic gap layers in contact with coil patterns, reducing magnetic saturation and eddy current loss, with a specific structure that maintains stable inductance from small to large magnetization currents, using non-magnetic or low-permeability materials with controlled thickness ratios and stress-resistant ferrite substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic gap layers are added to prevent magnetic saturation, then DC-superimposed characteristics are improved, but device complexity increases
Solution Approach 1:
The magnetic path is segmented into multiple regions by inserting non-magnetic gap layers between adjacent coil patterns on the same ferrite layer. This segmentation prevents magnetic saturation by dividing the flux path into separate regions, allowing each region to operate independently without saturating the entire magnetic path.
Solution Approach 2:
Non-magnetic gap layers are strategically positioned only in specific regions where coil patterns are in close proximity and magnetic saturation is most likely to occur. This localized approach prevents saturation in critical areas while maintaining magnetic path continuity in other regions, optimizing the balance between preventing saturation and maintaining inductance.
2Reliability
If multiple ferrite layers with coil patterns are laminated to form closed magnetic path, then inductance is increased, but magnetic saturation occurs at large magnetization currents
Solution Approach 1:
The magnetic path is segmented into multiple regions by inserting non-magnetic gap layers between adjacent coil patterns on the same ferrite layer. This segmentation prevents magnetic saturation by dividing the flux path into separate regions, allowing each region to operate independently without saturating the entire magnetic path.
Solution Approach 2:
Non-magnetic gap layers are inserted as intermediary elements between adjacent coil patterns to prevent direct magnetic coupling that would lead to saturation. These gap layers act as magnetic barriers that force flux to take alternative paths, preventing concentration of magnetic flux in single regions.
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 provides stable inductance and improved DC-superimposed characteristics, enhancing the performance of DC-DC converters in portable electronic devices by reducing magnetic saturation and maintaining high conversion efficiency at large currents.
Implementation Method 1
magnetic saturation partially occurs in a magnetic material in the laminated inductor by a DC magnetic field generated when a magnetization current is applied to the coil pattern
Implementation Method 2
a magnetic flux φa flowing around each coil pattern 43, and a magnetic flux φb flowing around pluralities of coils patterns 43 are formed
Implementation Method 3
a magnetic flux φa flowing around each coil pattern 43, and a magnetic flux φb flowing around pluralities of coils patterns 43 are formed in each of regions separated by the magnetic gap layer 44
Data Source
AI summary
The laminate device of the present invention comprises magnetic layers and coil patterns alternately laminated, the coil patterns being connected in a lamination direction to form a coil, and pluralities of magnetic gap layers being disposed in regions in contact with the coil patterns.