Multilayer Inductor Structure for High Inductance and Q Factor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inductors fail to achieve high inductance, excellent superimposed DC current characteristics, and a high Q factor simultaneously.
Innovation Solution
The inductor design includes a first magnetic layer with spherical magnetic particles and resin, and second and third magnetic layers with flat magnetic particles and resin, where the relative permeability of the second and third magnetic layers is higher than that of the first magnetic layer. The magnetic layers have specific concave portions that orient the magnetic particles for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single magnetic layer with uniform magnetic particles is used, then the manufacturing process is simple, but the inductance and Q factor cannot be optimized simultaneously
Solution Approach 1:
The magnetic layer is divided into multiple sub-layers (first magnetic layer, second magnetic layer, third magnetic layer) with different magnetic particle shapes and orientations. Each sub-layer serves a specific function: the first layer provides base inductance with spherical particles, while the second and third layers enhance Q factor with flat particles oriented in specific directions. This segmentation allows independent optimization of each layer's properties to achieve overall performance goals.
Solution Approach 2:
Different regions of the magnetic layer structure are assigned different qualities: spherical magnetic particles in the first layer for general inductance, and flat magnetic particles in the second and third layers for Q factor enhancement. The concave portions are strategically positioned to orient flat particles in specific directions. This local differentiation of material properties enables simultaneous optimization of inductance and Q factor that cannot be achieved with uniform structure.
2Reliability
If high inductance is achieved through increased magnetic material, then the Q factor deteriorates due to increased losses
Solution Approach 1:
The magnetic layer is segmented into functional zones: the first magnetic layer with spherical particles provides the primary inductance, while the second and third magnetic layers with flat particles and concave portions are specifically designed to reduce eddy current losses and improve Q factor. This functional segmentation decouples the inductance-providing function from the loss-reduction function, allowing both high inductance and high Q factor to coexist.
Solution Approach 2:
The patent employs a composite magnetic layer structure combining different types of magnetic particles (spherical and flat) with distinct magnetic properties. The spherical particles in the first layer provide high permeability for inductance, while the flat particles in the second and third layers, when oriented via concave portions, provide anisotropic magnetic properties that reduce losses. This composite approach creates a material system where the strengths of different particle types are combined while their weaknesses are mitigated.
3Loss of energy
If flat magnetic particles are used to improve Q factor, then the inductance decreases due to lower relative permeability
Solution Approach 1:
The magnetic layer is divided into functional sub-layers where the first layer with spherical particles is dedicated to providing high inductance through high relative permeability, while the second and third layers with flat particles are dedicated to enhancing Q factor. The concave portions in the second and third layers orient the flat particles to maximize their Q factor benefits. This segmentation allows each particle type to excel at its primary function without compromising the other.
Solution Approach 2:
The patent merges multiple magnetic layers with different particle types and orientations into a single integrated magnetic layer structure. The first magnetic layer with spherical particles and the second and third layers with flat particles are combined in a stacked configuration, creating a unified magnetic system that achieves both high inductance and high Q factor through the synergistic effect of its components.
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 achieves high inductance, excellent superimposed DC current characteristics, and an excellent Q factor, addressing the limitations of existing inductor technologies.
Implementation Method 1
a first magnetic layer having a first surface continuing in a surface direction, a second surface separated from the first surface by an interval in a thickness direction, and continuing in the surface direction, and an inner peripheral surface located between the first surface and the second surface, being in contact with an outer peripheral surface of the first wire and an outer peripheral surface of the second wire, the first magnetic layer containing approximately spherical-shaped magnetic particles and resin
Implementation Method 2
a second magnetic layer having a third surface being in contact with the first surface, and a fourth surface separated from the third surface in the thickness direction, the second magnetic layer containing approximately flat-shaped magnetic particles and the and resin; and a third magnetic layer having a fifth surface being in contact with the second surface, and a sixth surface separated from the fifth surface by an interval in the thickness direction, the third magnetic layer containing approximately flat-shaped magnetic particles and resin, wherein each of a relative permeability of the second magnetic layer and a relative permeability of the third magnetic layer is higher than a relative permeability of the first magnetic layer
Implementation Method 3
the third surface has a first concave portion caving in from a first facing portion facing the first wire in the thickness direction and a second facing portion facing the second wire in the thickness direction between the first facing portion and the second facing portion, the fourth surface has a second concave portion caving in from a third facing portion facing the first facing portion in the thickness direction and a fourth facing portion facing the second facing portion in the thickness direction between the third facing portion and the fourth facing portion
Data Source
AI summary
An inductor includes a first wire and a second wire, a first magnetic layer containing magnetic particles having an approximately spherical shape, a second magnetic layer containing magnetic particles having an approximately flat shape, and a third magnetic layer containing magnetic particles having an approximately flat shape. The relative permeability of each of the second magnetic layer and the third magnetic layer is higher than the relative permeability of the first magnetic layer. A fourth surface of the first magnetic layer has a second concave portion. A sixth surface of the third magnetic layer has a fourth concave portion.