Shielded Inductor Structure for Compact EMI Containment
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Solution Overview
Problem
Existing inductors face challenges with inefficient and cumbersome magnetic shielding that interferes with other electronic components, takes up valuable space, and is difficult to manufacture effectively.
Innovation Solution
A shielded inductor design featuring a core body with a shield covering at least part of its surface, optionally with an insulating material in between, and a shield configuration that complements the core body shape, using extensions and tabs for secure attachment, manufactured through pressure molding and stamping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If large electromagnetic shielding is used to cover a large target area, then electromagnetic radiation protection is improved, but device space is reduced and manufacturing complexity increases
Solution Approach 1:
The patent extracts the shielding function from a separate large shield and integrates it directly into the inductor core structure. The shield is formed as an internal cavity or chamber within the core body itself, eliminating the need for external shielding components and reducing overall device volume while maintaining electromagnetic radiation protection.
Solution Approach 2:
The patent merges the shielding function with the inductor core structure by forming the shield as an integral part of the core body. The core and shield are combined into a single molded structure, reducing manufacturing steps and assembly complexity while achieving both magnetic confinement and radiation shielding in one component.
2Object-affected harmful factors
If traditional shielding methods are used, then electromagnetic interference protection is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent combines the shield formation with the inductor core manufacturing process by using injection molding to create both the core and shield as a single integrated part. This eliminates separate manufacturing steps for the shield and simplifies assembly, making the overall manufacturing process easier and more efficient.
Solution Approach 2:
The patent changes the manufacturing approach from assembling separate shield and core components to molding them as a single integrated structure. This parameter change in the manufacturing process (from assembly to integrated molding) simplifies production while maintaining the electromagnetic interference protection function.
3Object-affected harmful factors
If shield is added to inductor, then electromagnetic interference protection is improved, but inductor size increases
Solution Approach 1:
The patent nests the shield within the inductor core structure by forming an internal cavity or chamber inside the core body. The shield is positioned within the core volume rather than adding external bulk, allowing the inductor to maintain a compact size while incorporating shielding functionality.
Solution Approach 2:
The patent utilizes the internal three-dimensional space of the core structure to position the shield, rather than adding shielding in the external dimensions. By using the core's internal volume for shield placement, the overall inductor footprint and external dimensions remain compact while achieving electromagnetic interference protection.
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 shielded inductor reduces electromagnetic interference, minimizes space usage, and enhances manufacturing efficiency while maintaining performance, with improved interference reduction and increased operating voltage.
Implementation Method 1
When a current flows through the coil, energy is stored temporarily in a magnetic field in the coil. When the current flowing through an inductor changes, the time-varying magnetic field induces a voltage in the conductor, according to Faraday's law of electromagnetic induction.
Implementation Method 2
The shield provides protection from electromagnetic fields by reducing the exposed portions of the core body
Data Source
AI summary
A shielded inductor and a method of making a shielded inductor are provided. The shielded inductor includes a core body surrounding a conductive coil, leads in electrical communication with the coil, and a shield covering at least parts of the outer surface of the core body. An insulating material may be provided between parts of the core body and parts of the shield. A method of making a shielded inductor is also provided.