Multilayer Magnetic Inductor for Better DC Superposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inductors exhibit insufficient DC superposition characteristics, which affect their performance in electronic devices.
Innovation Solution
An inductor design featuring a conducting wire with an insulating film and a magnetic layer composed of multiple layers with varying relative magnetic permeability, where the layers closer to the wire have lower permeability than those farther away, enhancing DC superposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer magnetic structure is used, then the device complexity is low, but the DC superposition characteristics are insufficient
Solution Approach 1:
The magnetic layer is divided into multiple layers (first magnetic layer, second magnetic layer, third magnetic layer) with different relative magnetic permeability values. Each layer serves a specific function: the first layer provides high permeability for inductance, the second layer provides low permeability for DC superposition characteristics, and the third layer provides intermediate permeability as a transition. This segmentation resolves the contradiction by achieving both low device complexity and high reliability through functional decomposition.
Solution Approach 2:
Different regions of the magnetic layer are assigned different magnetic permeability properties to optimize local performance. The first magnetic layer has high relative magnetic permeability (μr1 ≥ 10) for inductance enhancement, the second magnetic layer has low relative magnetic permeability (μr2 ≤ 5) for DC superposition characteristics, and the third magnetic layer has intermediate permeability (μr3) as a transition zone. This local differentiation resolves the contradiction between simple structure and superior DC superposition characteristics.
2Reliability
If high magnetic permeability material is used throughout, then inductance is high, but magnetic saturation occurs reducing DC superposition characteristics
Solution Approach 1:
The patent applies different magnetic permeability properties to different layers: the first magnetic layer uses high permeability material (μr1 ≥ 10) to achieve high inductance, while the second magnetic layer uses low permeability material (μr2 ≤ 5) to resist magnetic saturation and improve DC superposition characteristics. The third magnetic layer uses intermediate permeability (μr3) as a transition. This local quality differentiation resolves the contradiction between inductance strength and saturation resistance.
Solution Approach 2:
The magnetic layer comprises composite structures with different magnetic material properties arranged in specific layers. The first magnetic layer contains high-permeability magnetic particles, the second magnetic layer contains low-permeability magnetic particles, and the third magnetic layer contains intermediate-permeability magnetic particles. This composite material approach resolves the contradiction by combining materials with different magnetic properties to achieve both high inductance and high DC superposition characteristics.
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 inductor achieves improved DC superposition characteristics and inductance by carefully controlling the magnetic permeability and structure of the magnetic layer, reducing magnetic saturation and enhancing performance.
Implementation Method 1
the magnetic layer includes a first layer in contact with the circumferential surface of the wire, a second layer in contact with the surface of the first layer, and the n-th layer (n is a positive number of 3 or more) in contact with the surface of the (n−1)th layer, and in the two layers adjacent to each other in the magnetic layer, the relative magnetic permeability of the layer closer to the wire is lower than the relative magnetic permeability of the layer farther from the wire
Data Source
AI summary
An inductor includes a wire including a conducting line, and an insulating film disposed on an entire circumferential surface of the conducting line, and a magnetic layer embedding the wire. The magnetic layer contains a magnetic particle. The magnetic layer includes a first layer in contact with the circumferential surface of the wire, a second layer in contact with the surface of the first layer . . . and the n-th layer (n is a positive number of 3 or more) in contact with the surface of the (n−1)th layer. In the two layers adjacent to each other in the magnetic layer, the relative magnetic permeability of the layer closer to the wire is lower than the relative magnetic permeability of the layer farther from the wire.