Nested Coil Inductor Layout for Low-Height Resonant Power Design
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Solution Overview
Problem
The volume of resonant inductors used in vehicle power supplies is excessively large, making them difficult to integrate with existing products, especially when trying to achieve the required resonant inductance for wide output voltage ranges.
Innovation Solution
The inductor design features a magnetic core with a first inner coil and a first outer coil sequentially wound around a center pillar, forming two layers of coils, which reduces the overall height of the magnetic core while maintaining performance, and includes fillers and sparse winding to minimize magnetic core and copper wire losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If several resonant inductors are connected in series to achieve the required resonant inductance value, then the required inductance is met, but the volume of the inductor becomes excessively large
Solution Approach 1:
The patent applies nesting by placing the first inner coil inside the first outer coil, both surrounding the same first center pillar. This nested configuration allows multiple coils to occupy overlapping spatial regions rather than requiring separate volumes, thereby achieving the required resonant inductance with significantly reduced overall inductor volume compared to series connections of separate inductors
Solution Approach 2:
The patent transitions from a single-layer coil structure to a multi-layer structure by winding the first inner coil and first outer coil at different radial dimensions around the center pillar. This dimensional arrangement allows the coils to be stacked in space rather than arranged linearly, reducing the overall volume while maintaining the required inductance characteristics
2Volume of stationary object
If the magnetic core height is reduced to facilitate integration, then the inductor becomes easier to combine with existing products, but the coil winding space and magnetic path may be compromised
Solution Approach 1:
By nesting the first inner coil within the first outer coil, the patent maximizes the utilization of the magnetic core's vertical space. Both coils share the same magnetic path through the center pillar, allowing the magnetic core to maintain adequate height for proper magnetic flux circulation while the nested coils fit within the available radial and axial space
Solution Approach 2:
The patent segments the winding structure into multiple independent coils (first inner coil and first outer coil) that can be independently designed and optimized. This segmentation allows each coil to be positioned at optimal locations around the center pillar, maintaining effective magnetic coupling while accommodating reduced overall height constraints
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 reduces the overall height of the inductor, facilitating easier integration and use without compromising power or performance, and minimizes magnetic core and copper wire losses by optimizing coil spacing and winding methods.
Implementation Method 1
an inductor, which includes a magnetic core, a first inner coil, and a first outer coil
Data Source
AI summary
Disclosed is an inductor, including a magnetic core, a first inner coil and a first outer coil. The magnetic core includes a first base, a magnetic cover, a first center pillar and a first side wall. The first center pillar and the first side wall extend from the first base towards the magnetic cover. The first inner coil surrounds the first center pillar. The first outer coil surrounds the first center pillar. The first inner coil is wound between the first outer coil and the first center pillar. In the inductor, both the first inner coil and the first outer coil are wound around the first center pillar, thereby reducing the overall height of the magnetic core, which is convenient for users to design and use.