Low-Profile Inductor With Perpendicular Protrusion Electrodes
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Solution Overview
Problem
Conventional inductors for DC-DC converters face challenges in miniaturization due to the need for thick magnetic layers to prevent magnetic saturation, which limits their profile reduction and affects direct-current superimposition characteristics, especially under high load currents.
Innovation Solution
A low-profile inductor design without insulating layers, featuring a coil electrode section with perpendicular protrusion electrodes and a magnetic layer section made of magnetic powder and insulating resin, allowing for thinner magnetic layers and reduced profile while maintaining good direct-current superimposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If insulating layers are used in conventional inductor structures, then electrical insulation is provided, but the profile height increases and cannot be reduced
Solution Approach 1:
The patent removes the insulating layer component from the inductor structure. The coil electrode is directly formed on the magnetic layer without any insulating layer in between, extracting the insulation function by using the magnetic layer itself as the base structure that eliminates the need for separate insulating layers, thereby reducing profile height.
Solution Approach 2:
The magnetic layer serves multiple functions: it provides magnetic flux path, structural support, and eliminates the need for insulating layers. The coil electrode is directly formed on the magnetic layer, making the magnetic layer a multi-functional component that replaces both the magnetic core and the insulating layer structure.
2Length of moving object
If magnetic layers are made thin to reduce profile, then inductor size is reduced, but magnetic saturation occurs and direct-current superimposition characteristics deteriorate
Solution Approach 1:
The patent creates localized magnetic flux paths by forming the coil electrode directly on the magnetic layer with specific winding patterns. This local quality approach concentrates the magnetic flux in specific regions of the magnetic layer, improving the utilization of magnetic material and preventing saturation even with thin magnetic layers.
Solution Approach 2:
The patent transitions from a conventional layered structure to a direct-formed coil structure where the coil electrode is created directly on the magnetic layer surface. This dimensional change allows for more efficient magnetic flux distribution and better direct-current superimposition characteristics in thin-profile inductors.
3Reliability
If magnetic layers are made thick to prevent magnetic saturation, then direct-current superimposition characteristics improve, but profile height increases
Solution Approach 1:
The patent changes the structural parameters by eliminating insulating layers and directly forming the coil electrode on the magnetic layer. This parameter change allows for optimized magnetic flux distribution that prevents saturation with thinner magnetic layers, achieving both small profile and good direct-current superimposition characteristics.
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 prevents magnetic saturation and enhances direct-current superimposition characteristics, enabling a smaller, more efficient DC-DC converter with improved performance under high load conditions.
Implementation Method 1
A magnetic field caused by the first spiral electrode and a magnetic field caused by the second spiral electrode are directed toward substantially the same direction and are substantially in parallel with each other
Data Source
AI summary
An inductor includes a coil electrode section in which a first spiral electrode and a second spiral electrode are wound in substantially the same direction, lie in substantially the same plane, and are connected to each other by a connection electrode. The coil electrode section is sandwiched by the first magnetic layer and the second magnetic layer from both directions substantially perpendicular to the plane. A first protrusion electrode and a second protrusion electrode at ends of the first spiral electrode and the second spiral electrode that are opposite to the connection electrode extend in a direction substantially perpendicular to the plane, have a length at which each of the protrusion electrodes protrudes from the first magnetic layer, and define opposite end electrodes of the inductor. Arranging this low-profile inductor on a mounting circuit board achieves a low-profile DC-DC converter including a two-layer structure.