Magnetic Component Ridge Core Deposition
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Solution Overview
Problem
Current magnetic components, such as inductors and transformers, have poor fill factors leading to lower quality factors and higher costs due to inefficient winding of wire conductors around cores, resulting in higher flux leakage.
Innovation Solution
The method involves creating magnetic components with ridges on the core, depositing conductive materials, and removing portions to form continuous conductors with insulating gaps, allowing for improved winding patterns and connections between substrates to enhance the quality factor and reduce flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire conductors are wound around a core to form magnetic components, then the components can be manufactured with traditional methods, but the fill factor is poor resulting in lower quality factor and higher costs
Solution Approach 1:
The patent replaces the mechanical winding process with a deposition process where conductive material is deposited directly onto the core in a desired pattern. This eliminates the limitations of manual or automated wire winding and allows for precise control of conductor placement, width, and insulation, thereby improving fill factor and quality factor while maintaining ease of manufacture through scalable deposition techniques.
Solution Approach 2:
The patent changes the fundamental parameter of conductor formation from discrete wire winding to continuous material deposition. By controlling deposition parameters such as material thickness, deposition rate, and pattern definition, the process achieves superior fill factor and quality factor compared to traditional winding methods.
2Ease of manufacture
If wire conductors are wound around a core, then magnetic components can be formed, but flux leakage increases and quality factor decreases
Solution Approach 1:
The deposition-based conductor formation eliminates the gaps and irregularities inherent in wire winding, creating continuous, uniform conductive paths that minimize flux leakage. The precise control over conductor geometry and insulation ensures optimal magnetic coupling and reduced harmful electromagnetic effects.
3Device complexity
If traditional winding methods are used to create magnetic components, then the manufacturing process is simple, but the fill factor is poor leading to higher costs
Solution Approach 1:
The patent replaces the complex multi-step winding process with a single deposition step that directly creates the final conductor pattern. This increases fill factor by eliminating wasted space between windings and insulation layers, thereby reducing material costs and improving overall efficiency despite the introduction of deposition technology.
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 approach results in magnetic components with higher quality factors and lower flux leakage, while also reducing fabrication costs by optimizing the winding process.
Implementation Method 1
depositing one or more electrically conductive materials on the core
Data Source
AI summary
A method for making a magnetic component is provided. The method comprises providing a core with one or more ridges protruding from one or more surfaces of the core, depositing one or more electrically conductive materials on the core, and removing at least a portion of the one or more ridges to form one or more continuous conductors wound around the core. Each of the one or more continuous conductors defines at least one insulating gap. Further, a magnetic component and methods for making the magnetic component are also presented.