Parallel Flat-Wire Inductor Structure for Low-Resistance Cooling
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Solution Overview
Problem
Inductors in existing voltage converters experience excessive heat generation and poor heat dissipation due to high resistance components, leading to inefficiencies when handling large currents.
Innovation Solution
The design incorporates a flat-type wire inductor with a rectangular cross-section and parallel connections, utilizing a heat-dissipating member with high thermal conductivity to reduce direct-current resistance and enhance heat dissipation, thereby minimizing temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional coil component with drum core and winding is used, then the inductor structure is compact, but the resistance component is not sufficiently reduced and temperature rises above tolerable range when large current flows
Solution Approach 1:
The inductor is divided into multiple independent coil parts (first coil part, second coil part, etc.), each with its own drum core and winding. These segmented coil parts are arranged side by side and connected in parallel, allowing current to be distributed across multiple paths, thereby reducing the resistance component and heat generation in each individual coil part.
Solution Approach 2:
Multiple coil parts are merged into a single inductor component by connecting them in parallel between common terminal electrodes. The middle member integrates these coil parts into a unified structure, combining their current-carrying capabilities while maintaining individual thermal management for each coil part.
2Power
If multiple coil parts are arranged side by side, then the current carrying capacity increases, but cross talk between coil parts occurs
Solution Approach 1:
A middle member is introduced as an intermediary component positioned between adjacent coil parts. This middle member serves as a magnetic shield that blocks magnetic flux from one coil part from coupling into adjacent coil parts, thereby eliminating cross talk while allowing the coil parts to be arranged close together for compact design and high current capacity.
Solution Approach 2:
The inductor is segmented into multiple independent coil parts with magnetic shielding between them, allowing each coil part to carry current independently without magnetic interference from others, thus achieving high current capacity without cross talk.
3Productivity
If the inductor handles large current, then the power conversion efficiency improves, but heat generation exceeds heat dissipation capability
Solution Approach 1:
The inductor is segmented into multiple coil parts that can be independently thermally managed. Each coil part generates less heat when carrying a portion of the total current, and the segmented structure allows for better heat distribution and dissipation across the entire inductor component, preventing localized overheating.
Solution Approach 2:
The middle member not only provides magnetic shielding but also serves as a thermal management component. It facilitates heat dissipation from the coil parts and prevents thermal coupling between adjacent coil parts, allowing the inductor to handle large currents efficiently without excessive temperature rise.
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 configuration effectively reduces the direct-current resistance and improves heat dissipation, ensuring efficient operation and reduced noise in voltage converters, particularly in DC-to-DC converters.
Implementation Method 1
Each of the plurality of conductors is made of a flat-type wire having a rectangular cross section and includes a cylindrical winding section wound a specific number of turns, and the plurality of conductors are connected in parallel with each other
Implementation Method 2
improves heat dissipation, ensuring efficient operation and reduced noise in voltage converters
Data Source
AI summary
An inductor which avoids heat generation and heat dissipation problems, and has a reduced resistance component, when used in a voltage converter. An inductor is configured with a pair of outer electrodes disposed on both end portions of an element assembly and electrically connected to end portions of conductors. The conductors are made of a flat-type wire having a rectangular cross section, are placed side by side between the end portions, and include cylindrical winding sections, respectively, in which the flat-type wire in a long side direction of the rectangular cross section is wound the number of turns less than one about a thickness direction intersecting with a length direction connecting the pair of end portions along the thickness direction. A heat-dissipating member includes a portion being a partition between the conductors and a portion exposed on the top of an outer surface of the element assembly.