Laminated Inductor with Segmented Mixed Layers

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Solution Overview

Problem

Laminated inductors experience rapid reduction in inductance value and deteriorated DC superposition characteristics due to magnetic saturation when direct current is applied, and existing solutions do not adequately suppress external magnetic leakage.

Innovation Solution

The laminated inductor design includes first and second mixed layers formed with nonmagnetic material, positioned inside and outside the coil conductor respectively, to prevent local magnetic saturation and reduce external magnetic leakage, with conductive patterns electrically connected to function as a coil conductor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a magnetic gap portion is formed by replacing part of the magnetic layer with nonmagnetic substance, then DC superposition characteristics are improved, but external magnetic leakage is not sufficiently suppressed

Engineering Contradiction:

ImproveDC superposition characteristicsVSAvoidexternal magnetic leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The magnetic layer is segmented into multiple regions: first magnetic portions, second magnetic portions, and nonmagnetic portions arranged in a specific pattern. This segmentation allows different regions to serve different functions - some regions suppress magnetic saturation while others minimize magnetic leakage, resolving the contradiction between improving DC superposition characteristics and suppressing external magnetic leakage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the magnetic layer are given different properties and arrangements. The first magnetic portions are positioned to suppress saturation at the magnetic core, while the second magnetic portions are arranged to minimize external magnetic leakage. This local differentiation allows each region to optimize for its specific function, simultaneously achieving both improved DC superposition characteristics and reduced magnetic leakage.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If magnetic layers and conductive patterns are alternately laminated to form coil conductor, then miniaturization is achieved, but magnetic saturation occurs rapidly when direct current is applied

Engineering Contradiction:

Improveinductor sizeVSAvoidmagnetic saturation resistance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The magnetic layer is divided into first magnetic portions and second magnetic portions with different functions. The first magnetic portions are strategically positioned to suppress magnetic saturation at the magnetic core when direct current is applied, while maintaining the compact laminated structure for miniaturization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The magnetic layer comprises a composite structure of magnetic material and nonmagnetic material arranged in a specific pattern. This composite structure allows the inductor to maintain small size through lamination while the nonmagnetic portions prevent magnetic saturation, resolving the contradiction between miniaturization and magnetic saturation resistance.

Inventive Principle:

Principle #40Composite materials

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 effectively suppresses magnetic saturation and external magnetic leakage, resulting in improved DC superposition characteristics and reduced inductance value degradation with increasing direct current.

Implementation Method 1

when a direct current is applied to such a laminated inductor, an inductance value rapidly reduces as a result of an occurrence of magnetic saturation at magnetic substances

Methodology Applied

Scientific EffectMagnetic saturation: Magnetic Saturation

Implementation Method 2

the conductive patterns are electrically connected to one another and function as a coil conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS8193888B2Laminated inductor

Publication Date: 2012.06.05 MURATA MFG CO LTD

AI summary

This disclosure provides a laminated inductor capable of suppressing concentration of magnetic gap portions, preventing local magnetic saturation, and obtaining excellent DC superposition characteristics. In an embodiment of a laminated inductor, magnetic layers and coil conductors are alternately laminated. The laminated inductor includes plural first mixed layers and plural second mixed layers. Each first mixed layer includes a first nonmagnetic material portion between ones of the conductive patterns overlapping in a lamination direction and a second nonmagnetic material portion that is inside the coil conductor and connected to the first nonmagnetic material portion. Each second mixed layer includes a nonmagnetic material portion between ones of the conductive patterns overlapping in the lamination direction and a nonmagnetic material portion that is outside the coil conductor and is connected to the first nonmagnetic material portion. The plural first mixed layers and the plural second mixed layers are formed as different layers.