Multi-Layer Permeability-Enhancing Film Inductor Design
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Solution Overview
Problem
Conventional inductors face limitations in enhancing inductance, self-resonance frequency, and quality factor, as existing designs do not effectively utilize permeability-enhancing materials to improve these performance metrics.
Innovation Solution
The inductor incorporates a multi-layer permeability-enhancing film with a bi-layer or tri-layer structure, featuring a first ferromagnetic layer and an exchange-coupling layer, which exhibits exchange-coupling effects to align magnetic moments and enhance permeability, anisotropy field, and ferromagnetic resonance frequency, thereby improving inductance and quality factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer magnetic material is used, then the structure is simple, but the inductance, self-resonance frequency, and quality factor cannot be effectively enhanced
Solution Approach 1:
The patent applies composite materials by creating a multi-layer permeability-enhancing film structure consisting of ferromagnetic layers and exchange-coupling layers. This composite structure combines different magnetic materials with complementary properties to achieve enhanced inductance, self-resonance frequency, and quality factor that cannot be obtained with conventional single-layer magnetic materials alone.
Solution Approach 2:
The patent transitions from conventional single-layer to multi-layer film structure, adding the dimension of layering. By stacking multiple ferromagnetic and exchange-coupling layers, the invention achieves three-dimensional magnetic moment alignment and exchange coupling effects that enhance performance metrics beyond what planar single-layer structures can provide.
2Reliability
If magnetic particles are added to insulator layer, then ferromagnetic resonance frequency and quality factor are enhanced, but the permeability enhancement is limited
Solution Approach 1:
The patent creates a composite multi-layer film where ferromagnetic layers and exchange-coupling layers are systematically arranged. This composite structure provides controlled permeability enhancement through interfacial exchange coupling, achieving superior performance compared to simply dispersing magnetic particles in an insulator layer.
Solution Approach 2:
The patent optimizes the thickness parameters of individual layers and the overall multi-layer structure to achieve maximum permeability enhancement. By carefully controlling layer thicknesses and total film thickness, the invention achieves enhanced magnetic properties while maintaining manufacturability and avoiding excessive complexity.
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 design significantly enhances the anisotropy field and ferromagnetic resonance frequency, leading to improved inductance and quality factor performance, with the bi-layer structure achieving up to 540% improvement in anisotropy field compared to conventional designs.
Implementation Method 1
The two layers exhibit an exchange-coupling effect and include a first ferromagnetic layer of a first ferromagnetic material and an exchange-coupling layer magnetically coupled to the first ferromagnetic layer
Data Source
AI summary
An inductor includes: a substrate; an insulator layer; a conductive coil; and a permeability-enhancing film of a multi-layer structure. The multi-layer structure includes at least one repeating unit that has at least two layers. The two layers exhibit an exchange-coupling effect and include a first ferromagnetic layer of a first ferromagnetic material and an exchange-coupling layer.