Space-Efficient PCB Inductor with Toroidal and Cylindrical Sections
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Solution Overview
Problem
Conventional PCB-based inductor designs are not space-efficient, which hinders the miniaturization of electronic devices.
Innovation Solution
A space-efficient PCB-based inductor design featuring a combination of toroidal and cylindrical inductor turns connected in series, with longer turns in the cylindrical sections to maximize space utilization and magnetic field volume, utilizing top and bottom traces interconnected by inner and outer vias to form a continuous electrical path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional PCB-based inductor designs are used, then manufacturing simplicity is maintained, but space efficiency deteriorates
Solution Approach 1:
The inductor is divided into multiple discrete sections: first and second toroidal end sections, and first and second cylindrical side sections. Each section is formed by specific sets of inductor turns (first set, second set, third set, fourth set respectively) that are arranged in distinct geometric patterns. This segmentation allows each section to contribute differently to the overall magnetic field while optimizing space utilization on the PCB.
Solution Approach 2:
The inductor design transitions from conventional planar traces to three-dimensional cylindrical and toroidal structures formed by vertical vias and multi-layer PCB routing. The cylindrical side sections extend vertically through the PCB thickness, creating a three-dimensional current path that encloses greater magnetic field volume within a smaller planar footprint, thereby resolving the contradiction between area reduction and structural complexity.
2Volume of stationary object
If toroidal inductor turns are used, then magnetic field volume is improved, but electrical resistance increases
Solution Approach 1:
Different sections of the inductor have different trace lengths optimized for their specific functions. The cylindrical side sections have longer turns that enclose greater magnetic flux, while the toroidal end sections have shorter turns that provide efficient current entry and exit points. This local optimization allows the majority of the inductor length (in the cylindrical sections) to contribute to magnetic field generation, maximizing the ratio of useful magnetic field volume to total electrical resistance.
3Volume of stationary object
If inductor turns are extended to maximize magnetic field volume, then magnetic field volume is improved, but inductor size increases
Solution Approach 1:
The inductor design nests multiple functional sections within a compact PCB footprint. The cylindrical side sections are positioned adjacent to and between the toroidal end sections, creating a nested arrangement where the magnetic fields of different sections reinforce each other. This nesting allows the inductor to achieve high magnetic field volume without proportionally increasing the overall inductor size, as the sections share space efficiently on the PCB.
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 design achieves a high magnetic field volume with reduced size and lower electrical resistance compared to traditional toroidal inductors, efficiently utilizing PCB space while maintaining similar inductance values.
Implementation Method 1
Inductor design involves an arrangement of a coiled conductor wrapped around a core
Data Source
AI summary
A space-efficient Printed Circuit Board (PCB)-based inductor includes a first set of inductor turns formed on the printed circuit board and arranged to form a first toroidal end section, a second set of inductor turns formed on the printed circuit board and arranged to form a first cylindrical side section, a third set of inductor turns formed on the printed circuit board and arranged to form a second toroidal end section, and a fourth set of inductor turns formed on the printed circuit board and arranged to form a second cylindrical side section. The first toroidal end section, first cylindrical side section, second toroidal end section, and second cylindrical side section are connected in series.