Multi-Layer Inductor Mitigating Skin Effect
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Solution Overview
Problem
Existing inductors suffer from high resistive losses at high frequencies due to the skin effect, leading to lower quality factors and inefficiencies in electrical circuits, particularly in applications like RFID, wireless power transfer, and communication systems, where energy losses result in heating and reduced performance.
Innovation Solution
The multi-layer wire concept is introduced, with non-conducting or poorly conductive dielectric layers alternating with conducting layers to increase the effective cross-sectional area, reducing resistance and enhancing the quality factor by mitigating the skin effect and proximity effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wire wound or ceramic-based inductor structures are used, then the inductor can be manufactured with simple structure, but the electrical resistance increases at high frequencies due to skin effect
Solution Approach 1:
The conductor is divided into multiple parallel layers instead of using a single solid conductor. Each layer carries a portion of the current, and the total cross-sectional area is increased by stacking multiple thin conductive layers with dielectric spacers between them. This segmentation allows current to distribute more effectively across the conductor cross-section, reducing skin effect losses while maintaining manufacturability through layer-by-layer construction
Solution Approach 2:
The inductor uses a composite structure combining conductive layers (copper or other conductive material) with dielectric spacer layers. This composite construction creates a multi-layer conductor assembly where the dielectric material provides both electrical insulation and mechanical spacing, enabling increased effective conductor area without proportionally increasing overall volume, thus reducing resistance while maintaining ease of manufacture
2Loss of energy
If conductor cross-sectional area is increased to reduce resistance, then electrical resistance decreases, but the inductor volume increases
Solution Approach 1:
Instead of increasing conductor area in a single plane (which would increase volume), the invention stacks multiple thin conductor layers in the vertical dimension. The dielectric spacers enable this vertical stacking by providing electrical isolation and mechanical spacing. This dimensional approach increases the effective conductor cross-sectional area without proportionally increasing the overall inductor volume, as the increased area is achieved through vertical stacking rather than lateral expansion
3Loss of energy
If quality factor is improved by reducing resistive losses, then energy efficiency increases, but manufacturing complexity increases due to multi-layer structure
Solution Approach 1:
The manufacturing process is segmented into repetitive layers (conductor layer, dielectric spacer, conductor layer, etc.) that can be fabricated using standard PCB or wire-winding techniques. Each layer is independently manufacturable, and the repetitive nature allows for automated assembly and consistent quality control, reducing the impact of complexity on manufacturing while achieving reduced resistive losses through the multi-layer structure
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 higher quality factors, reduced energy losses, and improved efficiency in electrical circuits operating at high frequencies, enabling longer battery life, reduced heating, and enhanced performance in compact electronic systems.
Implementation Method 1
Existing inductors suffer from high resistive losses at high frequencies due to the skin effect
Implementation Method 2
reducing resistance and enhancing the quality factor by mitigating the skin effect and proximity effects
Implementation Method 3
increase the effective cross-sectional area, reducing resistance
Implementation Method 4
A change in electrical current elicits a corresponding magnetic flux proportional to the amount of current, which in turn, generates an electromotive force (EMF), measured in volts, that opposes the change in current
Data Source
AI summary
A multi-layer, multi-turn structure for an inductor having a plurality of conductor layers separated by layers of insulator is described. The inductor further comprises a connector electrically connected between the conductor layers. The structure of the inductor may comprise a cavity therewithin. The structure of the inductor constructed such that electrical resistance is reduced therewithin, thus increasing the efficiency of the inductor. The inductor is particularly useful at operating within the radio frequency range and greater.