Shielded Inductor with Thermal Insulation for Noise Suppression
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Solution Overview
Problem
Existing DC-DC converters with metal composite inductors face challenges in suppressing noise radiation while ensuring insulation and heat dissipation, leading to increased size and potential temperature-related issues.
Innovation Solution
An inductor design featuring a metallic magnetic core with a shielding member electrically coupled to the substrate, covered on top and side faces, and an insulating member with thermal conductivity, where the thicknesses of the shielding and insulating members are optimized based on noise frequency and breakdown voltage to minimize size and ensure noise suppression, heat radiation, and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding member is added to suppress noise radiation from the inductor, then noise suppression is improved, but device complexity and size increase
Solution Approach 1:
The patent combines the shielding member and insulating member into a single integrated component. The shielding member made of ferromagnetic material simultaneously provides noise suppression and electrical insulation functions, eliminating the need for separate insulating structures and reducing overall device complexity.
Solution Approach 2:
The shielding member is designed to perform multiple functions: it acts as both a noise shield and an insulating barrier between the inductor core and surrounding components. This multi-functional design reduces the number of separate components needed in the inductor assembly.
2Temperature
If an insulating member with thermal conductivity is added between the core and shielding member, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent merges the insulating function and thermal conduction function into a single insulating member. This member is positioned between the inductor core and shielding member to provide both electrical insulation and thermal management, eliminating the need for additional heat dissipation components.
Solution Approach 2:
The insulating member is designed with dual functionality: it provides electrical insulation between conductive parts while simultaneously serving as a thermal conduction path to dissipate heat from the inductor core. This multi-functional approach reduces overall device complexity.
3Object-affected harmful factors
If the shielding member and insulating member are made thicker to ensure adequate noise suppression and insulation, then noise suppression and insulation are improved, but device volume increases
Solution Approach 1:
The patent optimizes the thickness parameters of the shielding member and insulating member based on specific performance requirements. By carefully selecting and adjusting these dimensional parameters, the design achieves adequate noise suppression and insulation effectiveness while minimizing the overall volume of the inductor assembly.
Solution Approach 2:
The shielding member and insulating member are applied selectively in regions where noise suppression and insulation are most critical. This localized approach ensures adequate protection in key areas while avoiding unnecessary material usage in regions where such protection is less important, thereby reducing overall device volume.
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 reduces noise radiation, ensures insulation, and enhances heat dissipation, allowing for a compact design that prevents temperature-related drops in rated current and size increases.
Implementation Method 1
an insulating member arranged between the core and the shielding member and having thermal conductivity
Implementation Method 2
a shielding member electrically coupled to a ground of a substrate and arranged to cover a top face and three or more side faces of the core
Implementation Method 3
a thickness of the shielding member being set by applying electric resistivity of the shielding member, permeability of the shielding member, and a frequency of noise desired to be shielded by the shielding member to an expression for determining a depth of a skin of skin effect
Data Source
AI summary
An inductor includes a core made from a metallic magnetic material, a wire wound around the core, a pair of outer electrodes coupled to respective end portions of the wire, a shielding member arranged so as to cover a top face and three or more side faces of the core, and an insulating member arranged between the core and the shielding member and having thermal conductivity. The thickness of the shielding member is set by applying the electric resistivity and permeability of the shielding member and the frequency of noise desired to be shielded to an expression for determining the depth of a skin of skin effect. The thickness of the insulating member is set according to the breakdown voltage of the insulating member and the voltage with which insulation is desired to be ensured under a use environment of the inductor.