Multilayer Inductor Stacked Magnetic Layers High Coupling
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Solution Overview
Problem
Existing multilayer inductor devices with wire-wound choke coils around a common magnetic core face challenges in achieving a low profile and reduced size while maintaining a high degree of coupling between inductors, and those with separate inductors on a ferrite multilayer substrate have low coupling.
Innovation Solution
A multilayer inductor device with a magnetic multilayer body where multiple magnetic layers are laminated, and coil conductors are formed on these layers with via conductors passing through, allowing for high magnetic coupling between inductors by aligning their central axes and arranging them to sandwich each other, thereby increasing saturation current without increasing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wire-wound choke coils are wound around a common magnetic core to increase coupling, then the degree of coupling is improved, but the device profile and size cannot be reduced
Solution Approach 1:
The patent transitions from a planar arrangement of inductors to a three-dimensional stacked configuration where multiple inductor units are arranged vertically along the thickness direction of the magnetic core. This dimensional change allows for high coupling between adjacent inductors while maintaining a compact overall footprint, effectively resolving the contradiction between coupling degree and device size.
Solution Approach 2:
Multiple inductor units are nested within the same magnetic core structure, with each unit containing its own coil and magnetic path. The inductors share the common magnetic core infrastructure while maintaining independent winding structures, allowing dense packing and high coupling without increasing external dimensions.
2Ease of manufacture
If multiple inductors are formed in separate areas on a ferrite multilayer substrate, then manufacturing is simplified, but the degree of coupling between inductors becomes low
Solution Approach 1:
The patent merges multiple inductor units into a single integrated multilayer structure where coil conductors from different inductors are formed in the same layered substrate. The via conductors and magnetic layers are shared across inductors, achieving high coupling while maintaining manufacturability through standardized multilayer fabrication processes.
Solution Approach 2:
Instead of arranging inductors in separate planar areas, the patent stacks multiple inductor units vertically through the multilayer structure. This vertical arrangement in the thickness direction enables strong magnetic coupling between adjacent layers while preserving the advantages of multilayer manufacturing techniques.
3Stability of the object's composition
If inductors are arranged to overlap in plan view with coinciding central axes, then coupling is maximized, but magnetic flux saturation occurs more easily
Solution Approach 1:
The patent introduces magnetic flux barriers in specific locations within the magnetic core to create non-uniform magnetic permeability distribution. These barriers are strategically placed to redirect and balance magnetic flux paths, preventing concentration in certain areas and thereby increasing saturation current while maintaining high coupling between inductors.
Solution Approach 2:
The patent modifies the magnetic core structure by introducing flux barriers that change the local magnetic permeability parameters. This creates differentiated magnetic paths for adjacent inductors, allowing high coupling through the shared core while preventing flux saturation through the barriers that redirect excess flux.
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 solution achieves a high degree of coupling between inductors, preventing magnetic flux saturation and allowing for increased saturation current, effectively addressing the size and coupling limitations of existing technologies.
Implementation Method 1
the coil conductors composing each inductor are magnetically coupled to each other in the laminated direction
Implementation Method 2
the directions of magnetic fluxes occurring in the inductors the coil conductors of which are adjacent to each other in the laminated direction are opposite to each other
Data Source
AI summary
A multilayer inductor device (10) includes a magnetic multilayer body (100) in which magnetic layers (110, 120, 130, 140) are laminated in this order. Coil conductors (211, 212) having winding forms are formed on the magnetic layers (110, 130), respectively. The coil conductors (211, 212) are coupled to each other with via conductors (311, 312, 313) to compose a first inductor (L1). Coil conductors (221, 222) having winding forms are formed on the magnetic layers (120, 140), respectively. The coil conductors (221, 222) are coupled to each other with via conductors (321, 322, 323) to compose a second inductor (L2).