Segmented Coil Inductor with Insulating Ribbon
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Solution Overview
Problem
Existing power inductors face challenges in forming uniform coils with large aspect ratios due to manufacturing limitations, leading to instability and reliability issues.
Innovation Solution
The design includes a body with a magnetic material, a support member, a coil, and insulating walls, where the coil is electrically connected through the support member, and an insulating ribbon is used to cross from the outermost to the innermost insulating wall, enhancing structural stability and preventing short-circuits while increasing the coil's aspect ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a coil with large aspect ratio is formed, then the inductance increases and device miniaturization is achieved, but manufacturing precision deteriorates due to process limitations
Solution Approach 1:
The coil structure is divided into multiple segments with different thicknesses along its length. The first coil portion has a first thickness and the second coil portion has a second thickness different from the first, allowing each segment to be optimized independently for manufacturing feasibility while achieving the overall high aspect ratio configuration
Solution Approach 2:
Different portions of the coil are given different local properties (thickness variations) to optimize both manufacturing precision and electrical performance. The varying thickness distribution allows critical sections to be manufactured with higher precision while maintaining the overall high aspect ratio geometry
2Volume of moving object
If the coil aspect ratio is increased, then the inductor achieves smaller size, but structural stability deteriorates
Solution Approach 1:
Dividing the coil into segments with varying thickness provides structural reinforcement at critical locations while maintaining the high aspect ratio overall geometry, thus preserving structural stability during miniaturization
Solution Approach 2:
The thickness parameter of the coil is varied along its length rather than being uniform, with the first and second coil portions having different thicknesses. This parameter variation optimizes both structural stability and electrical characteristics while maintaining compact dimensions
3Reliability
If the coil aspect ratio is increased, then the inductance increases, but reliability deteriorates due to manufacturing limitations
Solution Approach 1:
Segmenting the coil into portions with different thicknesses allows each segment to be manufactured within feasible precision tolerances, thereby maintaining overall reliability while achieving the high aspect ratio configuration
Solution Approach 2:
By assigning different thickness qualities to different coil portions, the design accommodates manufacturing variations locally while ensuring overall reliability. Critical areas can be optimized for precision manufacturing
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 configuration allows for the creation of a structurally stable inductor with a high aspect ratio coil, reducing direct current resistance and improving reliability, enabling the production of inductors with enhanced performance.
Implementation Method 1
a body including a magnetic material
Data Source
AI summary
An inductor includes: a body including a coil and a magnetic material, and external electrodes disposed on an outer surface of the body. The coil is supported by a support member, and the support member may also support an insulating wall including an open-hole pattern having a shape corresponding to a pattern of the coil. An insulating ribbon formed so that a length thereof is greater than a width thereof may be additionally disposed on at least a portion of an upper surface of the insulating wall.