Radial-Permeability Inductor Core for Compact High-Current Power Stages
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Solution Overview
Problem
Conventional inductor components in power supply circuits are limited in achieving compact, efficient, and high current output due to their homogeneous magnetic permeability, which results in inefficient energy storage and distribution, particularly in planar circuit applications.
Innovation Solution
The development of an inductor device with a core fabricated from multiple types of magnetically permeable materials, where the magnetic permeability varies radially, allowing for a higher inductance value in a smaller form factor by optimizing magnetic flux distribution and permeability gradients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional inductors with homogeneous magnetic permeability are used, then the inductor can be manufactured with simple structure, but the inductance value per unit volume is limited and current handling capability is insufficient
Solution Approach 1:
The patent applies local quality by dividing the core into multiple regions with different magnetic permeability values. The first core region has a first magnetic permeability while the second core region has a second magnetic permeability that is different from the first. This spatial variation in material properties allows different parts of the core to contribute differently to flux generation, thereby increasing the overall inductance density and current handling capability without increasing the physical volume of the inductor.
Solution Approach 2:
The patent employs composite materials by combining multiple magnetic core materials with different permeability characteristics into a single integrated core structure. This composite approach enables the inductor to achieve superior performance metrics including higher inductance per unit volume and improved current handling capability, while maintaining a compact form factor that would not be achievable with homogeneous materials alone.
2Ease of manufacture
If conventional inductors are designed for planar circuit applications, then the inductor can be easily integrated into circuit boards, but the inductor size must be larger to achieve required inductance values
Solution Approach 1:
The patent implements local quality through a multi-region core structure where each region has optimized magnetic permeability characteristics. This allows the inductor to achieve high inductance values in a compact volume, making it suitable for integration into circuit boards where space is constrained. The differentiated core regions maximize the inductance density, enabling smaller physical dimensions while meeting required inductance specifications.
Solution Approach 2:
The patent applies parameter changes by varying the magnetic permeability parameter across different core regions. By strategically selecting and positioning core materials with different permeability values, the design optimizes the magnetic flux distribution to achieve maximum inductance within the available volume, thereby reducing the overall inductor size required for circuit board integration.
3Device complexity
If homogeneous magnetic permeability is used throughout the core, then the inductor structure is simpler, but the magnetic flux distribution is inefficient leading to lower inductance values
Solution Approach 1:
The patent applies local quality by creating distinct core regions with different magnetic permeability values optimized for their specific locations. The first core region with its first magnetic permeability and the second core region with its second magnetic permeability work together to create an efficient magnetic flux distribution pattern. This localized optimization of material properties significantly enhances the overall inductance value compared to homogeneous designs, while the regional division remains manageable in terms of manufacturing complexity.
Solution Approach 2:
The patent employs composite materials by integrating multiple magnetic materials with different permeability characteristics into a unified core structure. This composite construction enables superior magnetic flux distribution and higher inductance values compared to homogeneous materials, while the integration approach maintains reasonable manufacturing complexity through established fabrication techniques.
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 enables higher inductance values with reduced size, improved flux density distribution, and enhanced current handling capabilities, addressing the inefficiencies of conventional inductor designs.
Implementation Method 1
the core of the inductor device confines magnetic flux generated from current flowing through the electrically conductive path
Implementation Method 2
the magnetic permeability of the core varies as a function of a radial distance from the electrically conductive path
Implementation Method 3
magnetic flux generated from current flowing through the electrically conductive path
Data Source
AI summary
According to one configuration, an inductor device includes a core fabricated from multiple different types of magnetically permeable material. The inductor device includes an electrically conductive path extending through the core. A magnetic permeability of the core varies in magnitude depending on a distance with respect to the electrically conductive path.