Laminated Inductor Grain Size Gradient for Bonding and Permeability
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Solution Overview
Problem
Laminated inductors using soft magnetic alloys face challenges with material compatibility and bonding issues when different magnetic materials are used for the internal conductive wire forming region and the top/bottom cover regions, leading to poor bonding and potential shorting or breaking of internal conductive wires, especially as devices become smaller.
Innovation Solution
The use of soft magnetic alloy grains with larger grain sizes for the top and bottom cover regions, matching the composition and having a greater average grain size than those in the internal conductive wire forming region, improves magnetic permeability and bonding, preventing wire shorting and enhancing the device's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different magnetic materials are used for the internal conductive wire forming region and top/bottom cover regions to achieve higher magnetic permeability and L value, then the magnetic performance is improved, but the bonding between regions deteriorates due to mutual diffusion of constituents
Solution Approach 1:
The patent applies parameter changes by controlling the grain size of soft magnetic alloy particles - using finer grains (3-10 μm) for the internal conductive wire forming region and coarser grains (10-20 μm) for the top and bottom cover regions. This grain size differentiation optimizes both magnetic performance and bonding characteristics without causing material incompatibility issues
Solution Approach 2:
The patent uses composite materials by combining soft magnetic alloy particles with binder resin to form magnetic layers. The specific composition ratio (70-90 wt% soft magnetic alloy particles, 10-30 wt% binder resin) creates a composite structure that ensures good bonding between different regions while maintaining high magnetic permeability and L value
2Reliability
If soft magnetic alloy is used instead of ferrite to increase saturated magnetic flux density and rated current, then the electrical current capacity is improved, but the volume resistivity decreases leading to potential shorting of internal conductive wires
Solution Approach 1:
The patent applies local quality by differentiating the soft magnetic alloy particle grain size between regions - finer grains in the internal conductive wire forming region provide better insulation properties, while coarser grains in the cover regions provide better magnetic shielding. This local differentiation addresses both the shorting risk and magnetic performance requirements
Solution Approach 2:
The patent changes physical parameters by controlling the grain size distribution of soft magnetic alloy particles and optimizing the binder resin content. These parameter adjustments increase the effective volume resistivity while maintaining high saturated magnetic flux density, thus preventing wire shorting while preserving current capacity
3Volume of moving object
If device size is reduced to support smaller applications, then the compactness is improved, but the internal conductive wires become thinner and more susceptible to shorting or breaking
Solution Approach 1:
The patent applies parameter changes by optimizing the grain size of soft magnetic alloy particles to be in the range of 3-20 μm, with specific differentiation between regions. This fine-grain structure allows for compact device design while maintaining sufficient mechanical strength and electrical insulation to prevent shorting or breaking of thin internal conductive wires
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 enhances the magnetic permeability and L value of the laminated inductor while ensuring the internal conductive wires remain intact and the device's strength, supporting smaller device designs with improved bonding properties.
Implementation Method 1
the average grain size of the soft magnetic alloy grains constituting the top and bottom cover regions is greater than the average grain size of the soft magnetic alloy grains constituting the magnetic part in the internal conductive wire forming region
Data Source
AI summary
A laminated inductor having an internal conductor forming region, as well as a top cover region and bottom cover region formed in a manner sandwiching the internal conductor forming region between top and bottom; wherein the internal conductor forming region has a magnetic part formed with soft magnetic alloy grains, as well as helical internal conductor embedded in the magnetic part; and at least one of the top cover region and bottom cover region (or preferably both) is/are formed with soft magnetic alloy grains whose average grain size is greater than that of grains in the internal conductor forming region including the soft magnetic alloy grains constituting the magnetic part.