Large-Current Inductor With Segmented Cores
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Solution Overview
Problem
Conventional large-current inductors are hindered by their size, which conflicts with the downsizing trend in electronic appliances, particularly those using surface-mount technology (SMT), as they require greater height or length for optimal inductive performance.
Innovation Solution
A novel large-current inductor design featuring a configuration with multiple core and winding pieces, including first and second core members, coil members, and indentations, which enhances energy storage efficiency through mutual inductance while limiting large current flow via leakage inductance, allowing for high performance in both light and heavy loads within a small form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inductor has greater height or length, then inductive performance is improved, but the device size increases which conflicts with downsizing trends
Solution Approach 1:
The inductor is divided into multiple core members (first core member, second core member, third core member, fourth core member) with separate winding pieces. Each core member-winding piece combination functions as an independent inductive element, allowing the total inductance to be achieved through parallel or series configuration without requiring a single large structure. This segmentation enables high inductive performance while maintaining compact overall dimensions suitable for SMT applications.
2Volume of moving object
If multiple core members and winding pieces are used to reduce size, then device complexity increases
Solution Approach 1:
Multiple core members are laterally joined together to form an integrated core assembly, and multiple winding pieces are positioned on different core members to create a unified inductor structure. The lateral joining of core members and the coordinated arrangement of winding pieces simplify the overall assembly process while achieving the desired compact form factor and high inductive performance.
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 achieves efficient energy storage and current management, enabling high performance under varying loads while maintaining a compact form factor, thus addressing the size limitations of conventional inductors.
Implementation Method 1
The large-current inductor enhances efficiency of energy storage by mutual inductance
Implementation Method 2
limits large current flow by leakage inductance
Data Source
AI summary
The large-current inductor includes a first core member having a first winding piece, a second winding piece, a first indentation, and a second indentation; a second core member having a third winding piece, a fourth winding piece, a third indentation, and a fourth indentation; a third core member attached and joined to first lateral sides of the first and second core members; and a fourth core member attached and joined to second lateral sides of the first and second core members. A first coil member winds around the first and third winding pieces, and has its ends embedded into the first and third indentations. A second coil member winds around the second and fourth winding pieces, and has its ends embedded into the second and fourth indentations. The inductor enhances efficiency of energy storage by mutual inductance, and limits large current flow by leakage inductance.