Multilayer Common Mode Filter Layout for Stronger Coil Coupling
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Solution Overview
Problem
The existing multilayer common mode filter design suffers from reduced magnetic coupling between coils due to the separation of through-hole conductors by the magnetic core section, leading to inefficient magnetic interaction.
Innovation Solution
The design rearranges the coils and through-hole conductors within the nonmagnetic section to ensure adjacency, with the magnetic core section positioned to facilitate closer proximity of the through-hole conductors, enhancing magnetic coupling between the first and second coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the magnetic core section is placed between the through-hole conductors of the first and second coils, then the magnetic core can be properly positioned within the coil structure, but the through-hole conductors become separated and magnetic coupling between the coils is reduced
Solution Approach 1:
The patent merges the first and second through-hole conductors into a single integrated through-hole conductor that passes through both coils and the magnetic core section. This combining of separate conductors into one unified structure eliminates the separation problem while maintaining proper magnetic core positioning, thereby improving magnetic coupling between the coils.
Solution Approach 2:
The patent transitions from a planar arrangement where through-hole conductors are separated in the horizontal direction to a three-dimensional arrangement where a single through-hole conductor extends vertically through both coils and the magnetic core. This dimensional change allows the conductors to be adjacent in the laminated direction while maintaining the magnetic core's structural role.
2Reliability
If the through-hole conductors are placed close together to enhance magnetic coupling, then magnetic interaction improves, but the risk of short circuit between conductors increases
Solution Approach 1:
The patent segments the through-hole conductor into distinct sections: a first section within the first coil, a second section within the second coil, and a third section within the magnetic core section. These segmented portions are electrically isolated from each other by the nonmagnetic layer and magnetic core material, allowing close proximity for magnetic coupling while preventing short circuits through electrical insulation.
Solution Approach 2:
The magnetic core section and nonmagnetic layer serve as intermediary structures between the through-hole conductor sections. These intermediaries maintain close spacing for magnetic coupling while providing electrical insulation that prevents short circuits, thus mediating between the conflicting requirements of proximity and isolation.
3Reliability
If the coils are arranged with adjacent coil conductors in the laminated direction, then magnetic coupling is enhanced, but the device height increases
Solution Approach 1:
The patent nests the magnetic core section and through-hole conductors within the coil structure in such a way that components are integrated into each other's spatial envelope. The through-hole conductor is nested through the coils and magnetic core, and the coil conductors are arranged to nest adjacent to each other in the laminated direction, achieving enhanced magnetic coupling without significant height increase.
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 significantly improves magnetic coupling between the coils, allowing for enhanced performance while maintaining a low-profile structure and preventing short circuits.
Implementation Method 1
the first through-hole conductor and the second through-hole conductor are located in the first regional portion so as to be adjacent to each other... the first through-hole conductor and the second through-hole conductor are easy to be magnetically coupled. Therefore, the present invention successfully enhances the magnetic coupling between the first coil and the second coil.
Data Source
AI summary
A first coil is configured in such a structure that first and second coil conductors are connected by a first through-hole conductor. A second coil is configured in such a structure that third and fourth coil conductors are connected by a second through-hole conductor. The first and second coils are arranged in a nonmagnetic section consisting of nonmagnetic layers. A portion located inside the first coil and the second coil in the nonmagnetic section includes a first regional portion and a second regional portion adjacent to each other when viewed from a laminated direction of the nonmagnetic layers. The first and second through-hole conductors are located in the first regional portion so as to be adjacent to each other, when viewed from the laminated direction. A magnetic core section comprised of a magnetic material is located in the second regional portion when viewed from the laminated direction.