Planar Grooved Power Inductor for Low Resistance
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Solution Overview
Problem
Conventional power inductors face challenges in miniaturization, with high resistance and limited inductance per unit area due to non-planar structures and limited conductor thickness, which complicates automation and integration with other components in compact designs.
Innovation Solution
A planar discrete power inductor design featuring a ferrite core with patterned grooves on the top and bottom surfaces filled with conductive material, connected by through vias to form a closed magnetic loop, allowing for ultra-low resistance and high inductance per unit area, and enabling easy stacking and integration with other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional wire-wound or multi-layer inductor structures are used, then inductance can be achieved, but the structure becomes non-planar with high resistance and limited inductance per unit area
Solution Approach 1:
The patent transitions from conventional three-dimensional wire-wound or multi-layer structures to a planar two-dimensional structure by depositing conductive traces on the surface of a magnetic core substrate. This dimensional change enables lower resistance paths while maintaining compact footprint, directly resolving the contradiction between planar shape and resistance performance.
Solution Approach 2:
The patent replaces mechanical wire-winding processes with vapor deposition or sputtering techniques to form conductive traces. This substitution eliminates the complexity of automated winding while achieving precise control over trace geometry and electrical properties, resolving the contradiction between structural simplicity and electrical performance.
2Area of stationary object
If conventional inductor structures are used, then inductance is provided, but the footprint area is large and integration with other components is difficult
Solution Approach 1:
By adopting a planar configuration where conductive traces lie flat on the magnetic core substrate surface, the patent reduces the vertical height and overall footprint area. This enables better integration with other planar components in compact electronic assemblies, resolving the contradiction between small area and integration capability.
Solution Approach 2:
The planar structure with surface-mounted conductive traces allows the inductor to be easily integrated with other planar components and compatible with standard PCB mounting techniques. The universal planar interface enhances adaptability across different application scenarios, resolving the contradiction between compact area and versatility.
3Ease of manufacture
If wire is fed through a center hole in a doughnut shaped ferrite core, then a toroidal coil can be formed, but the process is complex and difficult to automate
Solution Approach 1:
The patent replaces the complex mechanical wire-feeding and winding process through the center hole with a vapor deposition or sputtering process that directly forms conductive traces on the substrate surface. This eliminates the need for automated winding equipment and complex tooling, dramatically simplifying manufacturing and enabling easy automation, thus resolving the contradiction between ease of manufacture and process complexity.
Solution Approach 2:
The patent extracts and eliminates the complex wire-feeding mechanism and center hole structure from the traditional toroidal coil design. By removing these unnecessary mechanical components and replacing them with direct surface deposition, the manufacturing process becomes significantly simpler and more amenable to automation, resolving the contradiction between manufacturing ease and device complexity.
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 planar structure achieves ultra-low resistance and high inductance per unit area, facilitating compact designs with small footprints and low manufacturing costs, while allowing for efficient stacking and integration with other components.
Implementation Method 1
A planar discrete power inductor design featuring a ferrite core with patterned grooves on the top and bottom surfaces filled with conductive material, connected by through vias to form a closed magnetic loop
Implementation Method 2
An inductor generally includes wire wound around a core of ferrite material. Power inductors operate as energy-storage devices that store energy in a magnetic field during the power supply's switching-cycle on time
Data Source
AI summary
An inductor may include a planar ferrite core. A first group of one or more grooves is formed in a first side of the ferrite core. A second group of two or more grooves is formed in a second side of the ferrite core. The grooves in the first and second groups are oriented such that each groove in the first group overlaps with two corresponding grooves in the second group. A first plurality of vias communicates through the ferrite core between the first and second sides of the ferrite core. Each via is located where a groove in the first group overlaps with a groove in the second group. A conductive material is disposed in the first and second groups of grooves and in the vias to form an inductor coil.