Multi-Surface Coil Component for Miniaturized Power Inductors
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Solution Overview
Problem
There is a need for highly efficient and miniaturized small and thin power inductors capable of operating at high current levels with reduced mounting area, while maintaining a certain degree of leakage inductance to minimize output current ripples, which existing inductor arrays fail to achieve without increasing size.
Innovation Solution
A coil component with a magnetic body having two cores, where first and second coil parts are wound in the same direction on one surface and third and fourth coil parts are spaced apart on the other surface, connected by external electrodes, allowing for increased coupling and leakage inductance adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If inductors are miniaturized to reduce mounting area, then mounting area is reduced, but leakage inductance decreases causing increased output current ripples
Solution Approach 1:
The inductor is segmented into multiple coil parts (first, second, third, and fourth coil parts) arranged on different surfaces of the magnetic body. This segmentation allows independent optimization of each coil part's positioning and winding, enabling miniaturization while maintaining adequate leakage inductance through strategic spacing of the third and fourth coil parts.
Solution Approach 2:
The patent transitions from planar coil arrangements to three-dimensional positioning by placing coil parts on different surfaces of the magnetic body. The first and second coil parts are disposed on one surface while the third and fourth coil parts are disposed on the other surface, utilizing the third dimension (depth/thickness) to achieve compact mounting area while preserving leakage inductance through vertical spacing.
2Reliability
If inductor size is increased to maintain leakage inductance, then leakage inductance is maintained, but mounting area increases
Solution Approach 1:
Multiple coil parts are nested within the three-dimensional structure of the magnetic body, with coil parts positioned on opposite surfaces and interconnected through the magnetic core. This nesting approach allows the inductor to maintain adequate leakage inductance through internal spatial arrangement rather than external size expansion, achieving compact mounting area while preserving electrical performance.
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 configuration enhances the coupling coefficient and adjusts leakage inductance to desired values, improving the efficiency of the inductor array without increasing the mounting area, effectively reducing inductor current ripples.
Implementation Method 1
first and second coil parts disposed on one surface of the substrate and wound in the same direction, and third and fourth coil parts disposed on the other surface of the substrate to be spaced apart from each other
Data Source
AI summary
There are provided a coil component and a board having the same. The coil component includes: a magnetic body including a substrate having two cores, first and second coil parts disposed on one surface of the substrate and wound in the same direction, and third and fourth coil parts disposed on the other surface of the substrate to be spaced apart from each other; and first to fourth external electrodes disposed on outer surfaces of the magnetic body and connected to the first to fourth coil parts.