Stacked Anisotropic Magnetic Core for Higher Saturation Current
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Solution Overview
Problem
Inductors using soft magnetic materials face limitations in maximum current due to magnetic flux saturation, leading to functional equivalence with air gaps and undesirably limited magnetic flux density in hybrid structures.
Innovation Solution
A magnetic core with stacked magnetically anisotropic layers, each having a hard axis angularly offset from its adjacent layer, preventing current saturation by varying magnetic moment orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soft magnetic materials are used in inductors, then magnetic flux density is improved, but maximum current is limited due to magnetic flux saturation
Solution Approach 1:
The magnetic core is segmented into multiple stacked layers, each with distinct magnetic anisotropy orientations. This segmentation allows each layer to contribute differently to the overall magnetic response, preventing simultaneous saturation across all layers and enabling higher current capability while maintaining high magnetic flux density.
Solution Approach 2:
Different regions (layers) of the magnetic core are given different magnetic properties through varying the easy axis orientation in each layer. This local differentiation in magnetic quality allows the structure to handle higher currents by distributing the magnetic stress across layers with different saturation characteristics.
2Reliability
If hybrid device structures combining soft magnetic materials with empty space are used, then saturation current is improved, but magnetic flux density is limited
Solution Approach 1:
The magnetic core uses a composite structure of multiple magnetically anisotropic layers with different easy axis orientations. This composite approach combines the benefits of high magnetic flux density (from soft magnetic materials) with enhanced saturation current capability (from the multi-layer anisotropic structure), eliminating the need for air gaps while achieving both goals.
3Reliability
If multiple stacked magnetically anisotropic layers with angularly offset hard axes are used, then current saturation is prevented, but device complexity increases
Solution Approach 1:
The magnetic core is divided into multiple thin stacked layers, each with controlled magnetic anisotropy. This segmentation approach prevents current saturation by ensuring that not all layers saturate simultaneously, while the layered structure itself provides a systematic way to manage the complexity through repetitive manufacturing processes.
Solution Approach 2:
The easy axis orientation parameter is systematically varied across different layers to create distinct magnetic responses. By controlling this parameter across multiple layers, the structure achieves saturation resistance without requiring complex geometries, as the complexity is managed through parameter variation rather than structural complexity.
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
Enhances magnetic field strength and inductance, allowing wider application of inductors without current saturation, supporting a variety of inductor shapes and sizes.
Implementation Method 1
a magnetic core including a plurality of stacked magnetically anisotropic layers, wherein each of the plurality of stacked magnetically anisotropic layers has a hard axis angularly offset from an adjacent hard axis of an adjacent magnetically anisotropic layer
Implementation Method 2
Components featuring soft magnetic materials, however, suffer from limitations in maximum current achievable in the device due to the saturation of magnetic flux produced from magnetic fields within the soft magnetic material(s)
Data Source
AI summary
Embodiments of the disclosure provide a structure and method for a magnetic core with stacked magnetically anisotropic layers. A structure of the disclosure provides a magnetic core including a plurality of stacked magnetically anisotropic layers. Each of the plurality of stacked magnetically anisotropic layers has a hard axis angularly offset from an adjacent hard axis of an adjacent magnetically anisotropic layer. An inductor coil is on the magnetic core.