Multi-Coil Power Inductor for Low-Loss Current Control
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Solution Overview
Problem
Existing power inductors with a chip structure fail to effectively control losses across the entire current range due to uniform coil characteristics, leading to inefficiencies in both low and high current sections.
Innovation Solution
A power inductor with multiple coils having different electrical characteristics is designed, where one coil pattern has a higher inductance and lower DC resistance for low currents, and another coil pattern with lower inductance and lower DC resistance for high currents, allowing for independent current paths and reduced losses across the entire current band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single chip inductor uses multiple coils with substantially the same characteristics, then the device complexity is reduced and manufacturing is simplified, but loss throughout the entire current section is not effectively controlled
Solution Approach 1:
The inductor chip is segmented into multiple independent coil units (first coil unit, second coil unit, third coil unit) with different electrical characteristics. Each coil unit has distinct inductance values and DC resistance values, allowing them to operate effectively in different current ranges. This segmentation enables optimized loss control across the entire current section while maintaining a unified chip structure.
Solution Approach 2:
Different regions of the inductor chip are designed with locally optimized characteristics. The first coil unit is designed with higher inductance for low current sections, while the second and third coil units are designed with lower inductance and lower DC resistance for high current sections. This local quality differentiation allows each coil unit to excel in its designated operating range, effectively controlling overall loss.
2Loss of energy
If multiple coils with different electrical characteristics are disposed in a single chip, then loss control throughout the entire current range is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple coil units with different electrical characteristics are merged into a single integrated chip structure. The first, second, and third coil units are fabricated together on one chip substrate, sharing common lead terminals and magnetic cores. This merging approach achieves optimized loss control across the entire current range while maintaining manufacturing efficiency through integrated fabrication processes.
Solution Approach 2:
The single chip inductor structure serves multiple functions simultaneously: it provides high inductance for low current operation through the first coil unit, and low DC resistance for high current operation through the second and third coil units. The unified chip design integrates multiple functions into a single component, achieving both performance optimization and manufacturing efficiency.
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 design significantly decreases power inductor losses throughout the entire current range, enhancing efficiency by optimizing inductance and DC resistance values for both low and high current sections.
Implementation Method 1
a first coil pattern (11) and a second coil pattern (12) which are different from each other and are disposed on the magnetic core
Implementation Method 2
a magnetic core and a first coil pattern (11) and a second coil pattern (12) which are different from each other and are disposed on the magnetic core
Data Source
AI summary
An inductor includes first and second coil patterns disposed in a single chip, and at least one common lead terminal electrically connected to respective end portions of the first and second coil patterns. The first and second coil patterns operate independently of each other, such that a range of a current passing through the first coil pattern and a range of a current passing through the second coil pattern are different from each other. The first and second coil patterns are coil patterns having different electrical characteristics.