PCB-Integrated Inductor and Antenna Coils for Higher Component Density
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Solution Overview
Problem
The challenge is to increase the number of electronic components that can be mounted on a printed circuit board (PCB) while maintaining efficient electrical connectivity and space efficiency, particularly in smaller and more complex electronic devices.
Innovation Solution
The integration of inductors and antennas directly onto the PCB by coiling a wire through the topmost and bottommost layers of the PCB to form a coil, with the option to include a cutout for an inductor core, allowing for adjustable inductance and optimized circuit performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electronic components are mounted on a PCB, then electrical connectivity and functionality are achieved, but the PCB area occupied by discrete components increases, reducing the number of components that can be mounted
Solution Approach 1:
The patent merges the inductor component with the PCB structure by integrating the coil directly into the board layers. The wire is coiled through multiple layers of the PCB, combining the function of the inductor with the structural and insulating properties of the PCB itself, thereby eliminating the need for separate discrete inductor components and freeing up PCB area for additional components.
Solution Approach 2:
The patent utilizes the third dimension (vertical stacking) by coiling the wire through multiple layers of the PCB. Instead of placing components only on the surface plane, the inductor extends through the thickness of the board, using available vertical space to create compact three-dimensional structures that reduce the footprint on the PCB surface.
2Adaptability or versatility
If discrete inductors are used, then inductance values are achieved, but the PCB area and device complexity increase
Solution Approach 1:
The patent enables dynamic adjustment of inductance values by providing a mechanism to vary the number of active turns in the coiled wire structure. By selectively connecting different portions of the coil or adjusting the magnetic core properties, the inductance can be tuned to achieve desired electrical characteristics while maintaining a compact integrated structure.
Solution Approach 2:
The patent achieves inductance adjustment by changing physical parameters of the integrated structure, such as the position or properties of a magnetic core inserted through the coil, or by altering the effective number of turns through selective electrical connections. These parameter changes allow tuning of inductance values without requiring separate discrete inductor components for each value.
3Productivity
If wire is coiled through PCB layers to form integrated inductors, then PCB area is reduced and component density increases, but manufacturing complexity increases
Solution Approach 1:
The patent segments the PCB into multiple functional layers, with the inductor coil formed by routing conductive material through specific layers and insulating layers in between. This segmentation allows the inductor structure to be integrated into the existing multi-layer PCB manufacturing process, where each layer can be prepared and connected using standard lamination and drilling techniques.
Solution Approach 2:
The patent makes the PCB structure multi-functional by having it simultaneously serve as the structural support, the insulating medium, and the conductive pathway for the inductor. The same PCB layers and materials that provide mechanical support and electrical isolation also form the magnetic coil structure, eliminating the need for separate inductor components and simplifying the overall manufacturing process.
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 allows for a higher density of electronic components on PCBs, improved electrical performance, and the ability to adjust inductance by varying the inductor core, which is particularly beneficial in compact electronic devices.
Implementation Method 1
a wire that is coiled through topmost and bottommost layers of the PCB one or more turns to form a coil of an inductor or an antenna
Data Source
AI summary
A printed circuit board (PCB) has electronic components of an electrical circuit mounted thereon. The PCB includes a wire that is coiled through the PCB one or more turns to form a coil of an inductor or an antenna that is integrated with the PCB. The PCB can include a cutout for accepting an inductor core. The shape and/or size of the inductor core can be varied to achieve a target inductance. Both ends of the wire can be electrically connected to corresponding nodes of the electrical circuit. One end of the wire can be electrically connected to a node of the electrical circuit, and the other end of the wire can be electrically connected to an antenna body.