Surface-Mounted Inductor Coil Layout for Larger Windings
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Solution Overview
Problem
Conventional surface mounted inductors face challenges in miniaturization and performance enhancement due to the complexity of the tablet shape and the need to reduce the winding axis section and cross-sectional area of the coil, which affects superimposed current and resistance values.
Innovation Solution
The coil is wound with lead-out ends positioned at the outer periphery, and the formed body is designed to expose coil surfaces on four side surfaces parallel to the winding axis, with the outer area of the formed body being similar to or smaller than the inner area of the coil, allowing for increased coil size and improved superimposed current and resistance values through a simplified manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the lead-out end of the coil is interposed between the pillar-shaped convex portion of the tablet and the inner wall surface of the molding die, then the coil can be embedded in the formed body, but the shape of the tablet becomes complicated and the size of the coil cannot be increased
Solution Approach 1:
The invention divides the formed body into two distinct regions: a first region where the coil is embedded with magnetic material, and a second region where the coil surface is exposed without magnetic material. This segmentation allows the coil to maintain a larger size while simplifying the tablet structure, as the tablet no longer requires complex pillar-shaped convex portions to position the lead-out ends.
Solution Approach 2:
The invention transitions from a conventional embedded coil structure to a partially exposed coil structure by utilizing the surface dimension of the formed body. The coil surface is exposed on the side surface of the formed body, allowing the coil to extend closer to the outer periphery and increase in size without complicating the tablet shape.
2Volume of moving object
If the winding axis section area or cross-sectional area of the conductive wire is reduced, then miniaturization is achieved, but the superimposed current value Idc and resistance value Rdc deteriorate
Solution Approach 1:
The invention applies different properties to different regions of the formed body: the first region contains magnetic material to provide shielding and flux concentration, while the second region exposes the coil surface to reduce dead space. This local differentiation allows the coil to maintain larger dimensions and better electrical characteristics without increasing the overall inductor size excessively.
Solution Approach 2:
The invention extracts the magnetic material from the region where the coil surface is exposed, creating a second region free of magnetic material. This extraction removes the constraint that previously limited coil size, allowing the coil to be larger and achieve better superimposed current and resistance values while the formed body overall remains compact.
3Object-generated harmful factors
If the whole coil is coated with magnetic material, then flux leakage is reduced, but the coil size is constrained and manufacturing complexity increases
Solution Approach 1:
The invention applies magnetic material selectively only in the first region where the coil is embedded, rather than coating the entire coil. This localized application of magnetic material is sufficient to reduce flux leakage in the critical embedded portion while avoiding the manufacturing complexity and space constraints of full coil coating.
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 design enables larger coil size and improved superimposed current and resistance values while simplifying the tablet structure and manufacturing process, reducing dead space and enhancing performance.
Implementation Method 1
a formed body incorporating the coil is formed by a compression molding method or a powder compacting method
Implementation Method 2
since the coil is embedded in the formed body formed with the sealing material containing the magnetic material, the whole coil is coated with the magnetic material, so that flux leakage can be reduced
Data Source
AI summary
A formed body incorporating a coil by using: a coil formed by winding a conductive wire, and a formed body incorporating the coil, the formed body being formed with a sealing material containing a resin and a magnetic material. The coil is formed by winding the conductive wire so that lead-out ends are positioned at an outer periphery of a wound portion. The formed body is formed so that surfaces of the coil are partially exposed on four side surfaces of the formed body which are parallel to a winding axis of the coil, and the area of a portion of the formed body outside the outer periphery of the wound portion is almost equal to or smaller than the area of a portion of the formed body inside an inner periphery of the wound portion of the coil.