Multilayer Inductor DC Superposition via Localized Insulator
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Solution Overview
Problem
Multilayer inductors experience reduced inductance values due to magnetic saturation and nonuniform magnetic flux distribution, particularly when a direct current is applied, as existing designs with nonmagnetic insulating layers either separate the magnetic path or fail to stabilize the conductive layer contact, leading to inefficient direct current superposition properties.
Innovation Solution
A multilayer inductor design featuring a laminate structure with first insulating layers made of magnetic material and conductive layers forming a helical coil, where a second insulating layer with lower magnetic permeability crosses the coil's magnetic paths and overlaps with the conductive layer, ensuring uniform magnetic flux distribution and preventing magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nonmagnetic insulating layer is placed between magnetic layers to prevent magnetic saturation, then direct current superposition property is improved, but the magnetic path is separated and inductance value is greatly reduced
Solution Approach 1:
The patent applies local quality by placing the low magnetic permeability insulating layer only at specific locations where magnetic flux concentration occurs (at the inner magnetic path and overlapping with conductive layers), rather than uniformly between all magnetic layers. This localized approach prevents magnetic saturation at critical points while preserving the overall magnetic path continuity and maintaining high inductance value.
Solution Approach 2:
The low magnetic permeability insulating layer acts as an intermediary element that modifies magnetic flux distribution. By having this layer cross the inner magnetic path and overlap with conductive layers, it serves as a mediator to control and uniformize magnetic flux density without completely blocking the magnetic path, thus improving direct current superposition property while maintaining inductance.
2Reliability
If nonmagnetic insulating ceramic is placed on magnetic ceramic to improve direct current superposition property, then magnetic saturation is reduced, but magnetic flux density becomes nonuniform and inductance value is rapidly reduced
Solution Approach 1:
The patent applies local quality by strategically positioning the low magnetic permeability insulating layer to cross the inner magnetic path and overlap with conductive layers in the stacking direction. This localized placement creates uniform magnetic flux distribution at critical regions where saturation occurs, rather than applying insulating material uniformly across all magnetic ceramic surfaces.
Solution Approach 2:
The patent transitions from a two-dimensional planar placement of insulating ceramic to a three-dimensional configuration where the insulating layer extends in the stacking direction and overlaps with conductive layers. This dimensional change ensures uniform magnetic flux distribution by addressing flux concentration in multiple spatial dimensions.
3Stability of the object's composition
If nonmagnetic insulating ceramic with large thickness is used to prevent nonuniformity, then magnetic flux distribution improves, but the magnetic path is separated and inductance value is greatly reduced
Solution Approach 1:
The patent applies local quality by placing the low magnetic permeability insulating layer only where magnetic flux concentration occurs (crossing the inner magnetic path and overlapping with conductive layers), rather than using thick insulating material throughout. This localized approach achieves uniform magnetic flux distribution while minimizing interference with the overall magnetic path and maintaining high inductance value.
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 design effectively improves direct current superposition properties and maintains a high inductance value by ensuring uniform magnetic flux and preventing magnetic saturation, even under increased current bias, while minimizing magnetic flux leakage.
Implementation Method 1
Magnetic saturation is most likely to be caused around a conductive layer
Implementation Method 2
a second insulating layer having a magnetic permeability lower than those of the first insulating layers is disposed
Implementation Method 3
the conductive layers being connected to form a helical coil
Data Source
AI summary
A multilayer inductor having a uniformly improved direct current superposition property and an increased inductance value is disclosed. The multilayer inductor contains a laminate of a plurality of first insulating layers and a plurality of conductive layers, and the conductive layers and through hole conductors are connected to form a helical coil in the laminate. A second insulating layer which has a magnetic permeability lower than those of the first insulating layers is disposed such that it crosses an inner magnetic path of the helical coil, and a margin of the second insulating layer overlaps with the conductive layer in the stacking direction and is in contact with the conductive layer in the overlap portion. The magnetic flux density in the laminate is likely to be highest in the overlap portion, and thus, the highest-density magnetic flux passes through the second insulating layer inevitably, whereby the direct current superposition property can be uniformly improved.