Planar Inductor with Embedded Ferrite and Split Coils
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Solution Overview
Problem
Traditional inductive devices, such as transformers and inductors, are often large and limited in topology and performance, especially in communication devices, due to the size and fragility of ferrites, making it difficult to integrate them into smaller communication devices without damaging the ferrites during assembly.
Innovation Solution
A planar inductor device design featuring a ferrite body embedded within a substrate with conductive pathways that include input, current-splitting, coil, and output sections, where conductive coils are helically wrapped around the ferrite body, providing a compact and robust inductive element with customizable inductance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire-wrapped ferrite inductors are used, then inductance performance is achieved, but device size becomes large and ferrite fragility causes assembly damage
Solution Approach 1:
The inductor is segmented into planar conductive traces on a substrate with embedded ferrite particles, eliminating the need for a single large ferrite core. This segmentation allows the inductor to be flattened into a planar structure that can be directly mounted on circuit boards without fragile wire-wrapping operations.
Solution Approach 2:
The traditional mechanical wire-wrapping process around ferrite cores is replaced with planar conductive traces fabricated on a substrate. This substitution eliminates the mechanical assembly steps that cause ferrite damage while achieving the same inductance function through electromagnetic coupling with embedded ferrite particles.
2Volume of moving object
If ferrite size is reduced to decrease inductor volume, then device compactness improves, but ferrite becomes more prone to damage during assembly
Solution Approach 1:
Multiple small ferrite particles are merged into a collective magnetic structure embedded within the planar substrate. Individually, each particle is small and robust; collectively, they provide the necessary magnetic flux density while being protected by the substrate structure, eliminating fragility issues.
Solution Approach 2:
The ferrite particles are embedded within a planar substrate structure that acts as a protective shell. This thin-film encapsulation protects the ferrite material from mechanical damage during assembly while maintaining the compact planar form factor.
3Reliability
If hand or machine wrapping is used to create conductive coils around ferrites, then inductance is achieved, but manufacturing complexity and space consumption increase
Solution Approach 1:
The mechanical process of wrapping conductive wire around ferrite cores is replaced with photolithographic fabrication of planar conductive traces on a substrate. This substitution dramatically simplifies manufacturing by using standard PCB fabrication processes instead of complex wire-wrapping operations.
Solution Approach 2:
The three-dimensional wire-wrapping process is transformed into a two-dimensional planar trace pattern on a substrate. This dimensional reduction simplifies the manufacturing process while achieving the same electromagnetic function through the planar geometry of the conductive paths.
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 solution enables the creation of smaller, more reliable inductive devices that can be easily integrated into communication devices, offering improved performance and flexibility in inductance adjustment while minimizing the risk of ferrite damage during assembly.
Implementation Method 1
Current flows through the wire and generates magnetic flux in the magnetic body
Data Source
AI summary
A planar inductor device includes a ferrite body and a conductive pathway, The ferrite body extends around an opening in the ferrite body. The conductive pathway includes an input section, a current-splitting section, a coil section, a current-combining section, and an output section connected with each other, the input section extending toward the opening in the ferrite body. The current-splitting section includes a plurality of conductive coils joined with the conductive pathway and electrically disposed parallel to each other. The coil section includes the conductive coils helically wrapped around the ferrite body. The current-combining section includes the conductive coils joined with each other. The output section includes the joined conductive coils extending out of the ferrite body.