Power Inductor with Parylene Insulation and Metal Powder Composite
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Solution Overview
Problem
Power inductors manufactured with metal powders face issues with decreased inductance due to heat, increased material loss at high frequencies, and poor insulation between coil patterns and the body, which affects their performance in modern portable devices.
Innovation Solution
A power inductor design incorporating a body made of metal powder, polymer, and heat conducting filler, with a parylene insulation layer of uniform thickness and a magnetic layer to enhance magnetic permeability, and multiple substrates for increased capacity, addresses these issues by improving thermal stability, insulation, and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal powders are used to manufacture the body, then saturation magnetization value is increased, but material loss increases due to eddy current and hysteresis at high frequency
Solution Approach 1:
The body is constructed as a composite material combining metal powders with insulating polymer material. The metal powders provide high saturation magnetization, while the polymer insulation between particles reduces eddy current losses. This composite structure resolves the contradiction by allowing the magnetic benefits of metal while mitigating the high-frequency energy losses through electrical insulation.
2Quantity of substance
If metal powders and polymer are used, then saturation magnetization is increased, but inductance decreases as temperature rises
Solution Approach 1:
The composite structure of metal powders embedded in polymer matrix provides thermal management benefits. The polymer material has lower thermal expansion and better thermal stability compared to pure metal, which helps maintain inductance characteristics at elevated temperatures while still providing the high saturation magnetization needed for modern power applications.
3Ease of manufacture
If coil pattern contacts metal powders, then manufacturing is simplified, but insulation between coil pattern and body deteriorates
Solution Approach 1:
The metal powder-polymer composite body inherently provides electrical insulation between the coil pattern and the body. The polymer matrix surrounding the metal particles creates an insulating barrier, eliminating the need for additional insulation layers while maintaining manufacturing simplicity and ensuring reliable electrical insulation.
4Quantity of substance
If ferrite material is used, then inductance characteristic is good, but saturation magnetization value is lower than metal material
Solution Approach 1:
The metal powder-polymer composite achieves saturation magnetization values exceeding traditional ferrite materials while maintaining low high-frequency losses. The polymer insulation between metal particles suppresses eddy currents, allowing the use of high-permeability metal powders without the energy losses that would otherwise limit their performance at high frequencies.
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 effectively prevents inductance reduction due to heating, enhances insulation and magnetic permeability, and increases the power inductor's capacity, ensuring better performance in high-frequency applications.
Implementation Method 1
the body may include a metal powder, a polymer, and a heat conducting filler
Implementation Method 2
an insulation layer formed between the coil pattern and the body, wherein the insulation layer is formed of parylene
Implementation Method 3
a body manufactured by using metal powders, so that saturation magnetization value may be relatively increased
Data Source
Figure 1~3
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AI summary
The present disclosure provides a power inductor, which includes a body, at least one substrate provided inside the body, at least one coil pattern provided on at least one surface of the substrate, and an insulation layer formed between the coil pattern and the body, wherein the insulation layer is formed of parylene.