Laminated Inductor with Two-Peak Particle Size Distribution
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Solution Overview
Problem
Conventional laminated inductors face challenges in achieving high magnetic permeability, high inductance, low resistance, and high rated current due to limitations in the proportion of metal magnetic material, particle size, and powder shape, which hinder the downsizing of devices.
Innovation Solution
A laminated inductor design utilizing soft magnetic alloy particles with a two-peak particle size distribution curve for the top and bottom cover areas and internal conductor forming area, where the particles are buried within the magnetic material part, enhancing magnetic permeability and bonding strength while preventing short-circuiting and wire breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the proportion of metal magnetic material is increased to achieve high magnetic permeability, then magnetic permeability improves, but pressure-bonding cannot be implemented together with internal electrodes and high forming pressure cannot be applied
Solution Approach 1:
The inductor is divided into multiple laminated sheets, each containing magnetic material particles and internal electrodes. This segmentation allows the magnetic material proportion to be increased in each sheet while maintaining the pressure-bonding process feasibility through layered construction.
Solution Approach 2:
The patent uses composite material structure combining metal magnetic material particles with binder material. This composite approach enables high proportion of magnetic material (50-95 wt%) while maintaining structural integrity and manufacturability through pressure-bonding.
2Quantity of substance
If particles larger than the width between internal electrodes are used to achieve high magnetic permeability, then magnetic permeability improves, but short-circuiting or disconnection occurs
Solution Approach 1:
The patent specifies different particle size requirements for different regions: particles in the magnetic material layer have diameter of 0.1-10 μm, while particles in the electrode layer have diameter of 1-20 μm. This local quality differentiation allows large particles for high magnetic permeability while preventing short-circuiting through proper particle size control in conductive paths.
3Quantity of substance
If amorphous or other magnetic powder of high magnetic permeability is used to increase the proportion of metal magnetic material, then magnetic permeability improves, but high powder strength or flat or other non-spherical shape causes manufacturing issues
Solution Approach 1:
The patent specifies precise particle diameter ranges (0.1-10 μm for magnetic material, 1-20 μm for electrodes) and compositional ratios to optimize both magnetic permeability and manufacturability. These parameter changes enable high magnetic material proportion while maintaining suitable powder characteristics for pressure-bonding.
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 design improves magnetic permeability, inductance, and reduces resistance, enabling higher rated currents and smaller device sizes by optimizing the particle distribution and composition of soft magnetic alloy particles.
Implementation Method 1
at least one of the top cover area and bottom cover area is formed by soft magnetic alloy particles exhibiting a two-peak particle size distribution curve
Implementation Method 2
internal conductors buried in the magnetic material part
Data Source
AI summary
A laminated inductor offers higher magnetic permeability, high inductance, low resistance and high rated current, while also supporting downsizing of device, by using a soft magnetic alloy as the magnetic material. Provided is a laminated inductor, comprising: an internal conductor forming area and a top cover area and a bottom cover area formed in a manner sandwiching the internal conductor forming area from above and below, wherein the internal conductor forming area has a magnetic material part formed by soft magnetic alloy particles, and internal conductors buried in the magnetic material part, and at least one of the top cover area and bottom cover area is formed by soft magnetic alloy particles exhibiting a two-peak particle size distribution curve (based on count).