Molded Wire Inductor With Oriented Magnetic Particle Layer
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Solution Overview
Problem
Existing inductors struggle to achieve high inductance while being miniaturized and power-efficient, and they are also inconvenient to produce in large quantities due to complex lamination processes.
Innovation Solution
The development of an inductor with a wire covered by a magnetic layer containing a high volume percentage of magnetic particles and a binder, where the magnetic particles are anisotropic and oriented in specific regions to enhance inductance and DC superposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inductor uses conventional lamination of conductive layers made of conductive paste, then the inductor can be manufactured, but the manufacturing process becomes complex and inconvenient for large-scale production
Solution Approach 1:
The patent extracts the complex lamination process by replacing it with a single molded body structure. The inductor core is formed as one integrated piece containing the coil, eliminating the need for multiple conductive layer laminations and significantly simplifying the manufacturing process while maintaining electrical functionality
Solution Approach 2:
The patent merges the coil structure and magnetic core into a single molded body. The coil is embedded within the molded core material, combining what were previously separate manufactured components into one integrated structure that can be produced in a single molding operation
2Reliability
If the inductor uses conventional structures, then the manufacturing process is simple, but the inductance cannot meet the demand for higher performance and miniaturization
Solution Approach 1:
The patent changes the magnetic properties of the molded body by incorporating magnetic particles into the resin matrix. This transforms the core material from non-magnetic or weakly magnetic to strongly magnetic, significantly enhancing the inductance of the coil while maintaining the simple molded structure
Solution Approach 2:
The patent uses a composite material consisting of resin and magnetic particles to form the molded body. This composite structure combines the ease of molding resin with the magnetic properties of the particles, achieving both high inductance and manufacturing simplicity
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 proposed inductor achieves excellent inductance and is simpler to produce, with improved DC superposition characteristics due to the strategic orientation of anisotropic magnetic particles and the use of a binder with a cured thermosetting component.
Implementation Method 1
the magnetic layer contains a magnetic particle and a binder; in a peripheral region of the wire, a filling rate of the magnetic particle is 40% by volume or more
Implementation Method 2
the magnetic particle includes an anisotropic magnetic particle; the anisotropic magnetic particle is orientated in a portion adjacent to the wire in the magnetic layer
Implementation Method 3
the binder contains a cured product of a thermosetting component in a B-stage state
Data Source
AI summary
An inductor includes a wire, and a magnetic layer covering the wire. The wire includes a conducting line, and an insulating layer covering the conducting line. The magnetic layer includes a magnetic particle and a binder. In a peripheral region of the wire, a filling rate of the magnetic particle is 40% by volume or more. The peripheral region is a region of the magnetic layer traveling outwardly from an outer peripheral surface of the wire by 1.5 times an average of the longest length and the shortest length from the center of gravity C of the wire to an outer surface of the wire in a cross-sectional view.