Stacked Flat-Coil Inductor for High Coupling in Small Footprints
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Solution Overview
Problem
Conventional inductors used in multiphase power supply systems face limitations when high currents are required, as they struggle to achieve a high enough coupling coefficient to efficiently handle these currents.
Innovation Solution
The development of a small-sized inductor with a cuboid magnetic core and four overlapping flat coil elements, where the ends of the coil elements are bent to form external electrodes, enhancing the coupling coefficient while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the area by which the plurality of coils face each other is increased to increase the coupling coefficient, then the coupling coefficient is improved, but the device size increases making it difficult to use conventional electrode arrangements
Solution Approach 1:
The patent transitions from planar coil arrangements to a three-dimensional stacked configuration where four flat coils are arranged in layers along the vertical direction. This dimensional change allows the coils to face each other across multiple levels, increasing the effective coupling area without expanding the horizontal footprint of the device.
Solution Approach 2:
The patent embeds multiple flat coils within a single magnetic core structure, with each coil nested in its own groove. The coils are stacked vertically like nested dolls, with each layer containing a complete coil structure. This nesting approach maximizes the use of vertical space to achieve high coupling coefficients while maintaining a compact overall device size.
2Ease of manufacture
If conventional electrode arrangements are used in the increased area design, then the manufacturing process is simple, but the device becomes too large for practical applications
Solution Approach 1:
The patent combines multiple coil windings into a single integrated flat coil structure where the coil pattern is formed as one continuous conductive path. The external electrodes are positioned at the ends of this integrated structure, merging what would traditionally require separate components and complex interconnections into a single manufacturable unit.
Solution Approach 2:
The patent replaces traditional three-dimensional wire winding processes with a planar pattern formation process. The flat coils are created using printing or lamination techniques on insulating substrates, substituting mechanical wire manipulation with more precise and scalable planar fabrication methods that are easier to manufacture at high volumes.
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 a high-current handling inductor with a high coupling coefficient, effectively addressing the limitations of conventional inductors in multiphase power supply systems.
Implementation Method 1
an inductor including a plurality of coils coupled at a coupling coefficient of approximately 0.6
Implementation Method 2
a magnetic core having a cuboid shape, formed by pressure-molding a mixture of magnetic material powder and a binder
Data Source
AI summary
An object of the present disclosure is to achieve a small-sized inductor capable of handling a high current, and having a high coupling coefficient. Inductor includes magnetic core and coil element embedded in magnetic core. Coil element includes at least four flat coils, and first coil element, second coil element, third coil element, and fourth coil element are provided in an overlapping manner. Ends of each coil element protrude from bottom surface, and are bent along bottom surface, to form external electrode. Ends of first coil element and ends of third coil element are bent toward first side surface. Ends of second coil element and ends of fourth coil element are bent toward second side surface.