Laminated Inductor with Permeability Gap for DC Superposition
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Solution Overview
Problem
Laminated-type inductance elements fail to achieve a stair-like direct-current superposition characteristic, leading to a rapid decrease in inductance value due to magnetic saturation, making them unsuitable for DC-DC converters.
Innovation Solution
An electronic component with a laminated body and a spiral coil, featuring a gap between the coil and a second insulating layer with lower magnetic permeability, allowing for a stair-like direct-current superposition characteristic by maintaining inductance value stability across varying current levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the first nonmagnetic body layer is disposed to cross the coil forming an open magnetic-path structure, then rapid decrease in inductance value due to magnetic saturation is prevented, but the inductance value monotonously and gradually decreases with increase in direct current
Solution Approach 1:
The magnetic path is divided into segments with different magnetic permeability characteristics. The first magnetic body layer with high magnetic permeability handles low-current conditions, while the second magnetic body layer with low magnetic permeability handles high-current conditions. This segmentation creates distinct operational regions that produce the stair-like characteristic.
Solution Approach 2:
The inductance element uses a composite magnetic structure combining two magnetic body layers with different magnetic permeability properties. This composite approach allows the element to leverage the advantages of both high-permeability materials (for low-current stability) and low-permeability materials (for high-current stability), achieving the desired stair-like direct-current superposition characteristic.
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
The component achieves a stair-like direct-current superposition characteristic, ensuring a sufficiently large inductance value at low output currents and stable inductance at high output currents, enabling effective application in DC-DC converters.
Implementation Method 1
a second insulating layer disposed on the laminated body at a predetermined distance from the coil, the distance being viewable as a gap between the coil and the second insulating layer when viewed in a plan view from a coil axis direction of the coil, and the second insulating layer having a magnetic permeability lower than that of the first insulating layers
Implementation Method 2
a coil disposed in the laminated body
Data Source
AI summary
An electronic component having a coil includes a laminated body formed by laminating a plurality of magnetic body layers. The coil is formed by connecting coil electrodes in the laminated body. Nonmagnetic body layers are disposed on the laminated body to have a gap with the coil when seen in a plan view from a coil axis direction of the coil. The embodiment of an electronic component has a stair-like direct-current superposition characteristic.