Power Inductor Core Structure Using Graded Magnetic Powder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power inductor devices and manufacturing methods fail to meet the increasing demands of electronic products for high inductance value and saturation current capability while maintaining low production costs, due to issues with magnetic powder material density and loss control.
Innovation Solution
A power inductor device comprising multiple magnetic core bodies made from iron-based magnetic powders with varying particle sizes mixed with an adhesive, combined through a heating and pressing molding process to enhance density and inductance, reducing material loss and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If composite magnetic material is used to increase inductance value, then inductance value is improved, but production cost and material loss are not easy to control
Solution Approach 1:
The patent applies parameter changes by using iron-based magnetic powder with specifically controlled particle size distribution (first particle size smaller than second particle size, which is smaller than third particle size) and controlled adhesive content (1.5%-20% by weight). This parameter optimization enables achieving high inductance values while maintaining cost control and reducing material loss through improved packing efficiency and reduced air gaps.
Solution Approach 2:
The patent uses composite magnetic material composed of iron-based magnetic powder mixed with adhesive, where the magnetic powder contains multiple particle sizes (first, second, and third particle sizes). This composite structure improves density and inductance value while the optimized composition ratio controls production cost and material loss.
2Manufacturing precision
If pre-pressing process is used to increase density, then density is improved, but final product still cannot meet specific specs
Solution Approach 1:
The patent applies parameter changes by using iron-based magnetic powder with specifically controlled particle size distribution (first particle size smaller than second particle size, which is smaller than third particle size) and controlled adhesive content (1.5%-20% by weight). This parameter optimization enables achieving high inductance values while maintaining cost control and reducing material loss through improved packing efficiency and reduced air gaps.
Solution Approach 2:
The patent applies preliminary action through the heating and pressing molding process that occurs before final product completion. This process closely combines the magnetic core bodies with the metal conductor under controlled temperature and pressure, achieving the required density and structural integrity in advance, allowing the final product to meet specific specifications.
3Ease of manufacture
If single magnetic material is used, then manufacturing is simple, but cannot meet requirements of inductor product
Solution Approach 1:
The patent uses composite magnetic material composed of iron-based magnetic powder mixed with adhesive, where the magnetic powder contains multiple particle sizes (first, second, and third particle sizes). This composite structure improves density and inductance value while the optimized composition ratio controls production cost and material loss.
Solution Approach 2:
The patent applies parameter changes by using iron-based magnetic powder with specifically controlled particle size distribution (first particle size smaller than second particle size, which is smaller than third particle size) and controlled adhesive content (1.5%-20% by weight). This parameter optimization enables achieving high inductance values while maintaining cost control and reducing material loss through improved packing efficiency and reduced air gaps.
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 improves the uniformity of magnetic powder filling, increases the weight and density of the final product, enhancing inductance value and reducing production costs, allowing for mass production with improved yield and reduced mold loss.
Implementation Method 1
The first magnetic core body, the second magnetic core body, the third magnetic core body and the metal conductor being closely combined by a heating and pressing molding process
Implementation Method 2
The first magnetic core body, the second magnetic core body, the third magnetic core body and the metal conductor being closely combined by a heating and pressing molding process
Data Source
AI summary
A power inductor device and a manufacturing method thereof are provided. The power inductor device includes a first magnetic core body, a second magnetic core body, a third magnetic core body and a metal conductor. The first magnetic core body is formed by a first magnetic powder, the second magnetic core body is formed by a second magnetic powder and the third magnetic core body is formed by a third magnetic powder. The metal conductor is disposed between the columnar body and the groove. The first magnetic core body, the metal conductor, the second magnetic core body and the third magnetic core body are closely combined to obtain an integrated power inductor structure. The first magnetic powder, the second magnetic powder and the third magnetic powder include an iron-based magnetic powder having the large particle size, the medium particle size and the small particle size.