Nested Conductor Inductor for Miniaturization

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Solution Overview

Problem

Conventional inductors face challenges in reducing size due to difficulties in minimizing the intervals of adjacent conductor patterns, which limits further miniaturization of winding type inductors used in compact electronic devices.

Innovation Solution

The design incorporates a magnetic body with a conductor that includes a first conductor and a second conductor covering its periphery, formed by patterning and electroplating, allowing for closer spacing of adjacent patterns and increased inductance while reducing external size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional winding type inductor structure is used, then DC resistance can be reduced by securing cross sectional area of conductor patterns, but inductor size cannot be further reduced due to difficulty in reducing intervals of adjacent conductor patterns

Engineering Contradiction:

ImproveDC resistanceVSAvoidinductor size

Core Design Contradiction:

Loss of energyVSVolume of moving object

Solution Approach 1:

The conductor is formed with an inner conductor and an outer conductor that surrounds the inner conductor, creating a nested structure. This allows the conductors to be closely spaced while maintaining sufficient cross-sectional area for low DC resistance, effectively nesting one conductor within the space occupied by another.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The invention transitions from a planar conductor layout to a three-dimensional nested conductor structure. By utilizing the radial dimension with the outer conductor surrounding the inner conductor, the design achieves closer spacing without compromising the cross-sectional area needed for low resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If intervals of adjacent conductor patterns are reduced, then inductor size can be reduced, but manufacturing difficulty increases

Engineering Contradiction:

Improveinductor sizeVSAvoidmanufacturing difficulty

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

A base layer is formed beforehand to provide a foundation for the conductor patterns. The inner conductor is formed on this base layer, and the outer conductor is subsequently formed to surround the inner conductor. This preliminary preparation simplifies the subsequent formation of closely-spaced nested conductor structures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conductor is segmented into an inner conductor and an outer conductor with distinct formation steps. The inner conductor is formed first, followed by the outer conductor that surrounds it. This segmentation allows each conductor to be manufactured independently with appropriate spacing, reducing overall inductor size while maintaining manufacturability.

Inventive Principle:

Principle #1Segmentation

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 approach enables a reduction in inductor size by approximately 10% to 20% while maintaining or increasing inductance, and reduces DC resistance, allowing for higher current flow through the inductor.

Implementation Method 1

formed by patterning and electroplating

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS11610721B2Inductor

Publication Date: 2023.03.21 SHINKO ELECTRIC IND CO LTD

AI summary

An inductor includes a magnetic body, and a conductor embedded in the magnetic body. The conductor includes a first conductor, and a second conductor covering a periphery of the first conductor.