Magnetic Shell Coupled Inductor Structure for Compact PCB Layouts
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Solution Overview
Problem
Inductors occupy significant space in electronic circuits, particularly in small portable devices, leading to complex circuit designs with reduced performance.
Innovation Solution
A compact inductor design featuring a first wire covered by non-conductive material, surrounded by a magnetized shell with gaps, and optionally including additional wires and channels to enhance inductance and control saturation current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inductor designs are used, then inductance performance is achieved, but circuit board space consumption increases
Solution Approach 1:
The patent embeds the inductor structure within a magnetized shell, nesting the wire and non-conductive material inside the shell structure. This nested configuration allows the inductor to achieve its inductance function while being contained within a compact footprint, thereby reducing the space occupied on the circuit board while maintaining performance
Solution Approach 2:
The patent utilizes three-dimensional space by creating a shell structure that surrounds the wire in multiple dimensions. The magnetized shell extends in height and circumference, utilizing vertical and radial dimensions rather than only horizontal plane, thereby achieving high inductance in a compact footprint area
2Area of stationary object
If minimal number of inductors are used to save space, then circuit board space is reduced, but circuit design complexity increases and performance reduces
Solution Approach 1:
The magnetized shell structure serves multiple functions simultaneously: it provides magnetic coupling for inductance, acts as a structural housing, and enables compact integration. This multi-functionality allows a single inductor component to achieve complex electromagnetic functionality without requiring additional supporting structures, thereby reducing overall circuit complexity
3Area of stationary object
If compact inductor design is implemented, then space consumption is reduced, but inductance level may be compromised
Solution Approach 1:
The patent employs a composite structure combining wire, non-conductive material, and magnetized shell. The magnetized shell material provides high magnetic permeability, which concentrates and enhances the magnetic field generated by the wire, thereby achieving high inductance values in a compact configuration. The composite structure allows optimization of each material's properties to maximize inductance while minimizing space
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 a high level of inductance while minimizing space, allowing for more efficient use of circuit board space and improved performance in power supply, voltage regulation, and wireless circuits.
Implementation Method 1
The shell may include at least one magnetized layer
Implementation Method 2
Inductors may be used to resist fluctuations of an electric current. The current stabilizing property of inductors makes them useful in power supply circuits and voltage regulating circuits
Data Source
AI summary
An inductor is disclosed, including a first wire, a non-conductive material, and a shell. The non-conductive material may cover the first wire, with a portion of each end of the first wire uncovered. The shell may include a top portion and a bottom portion and include at least one magnetized layer and at least one gap between the first portion and the second portion. The shell may also surround a portion of the non-conductive material.