Swing-Type Inductor with Contoured Core for High Current
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Solution Overview
Problem
Conventional inductor components face challenges in miniaturization and cost-effectiveness while maintaining performance, especially in high current and high power applications, as they struggle to maintain constant current ripple and efficiency across varying load conditions.
Innovation Solution
The development of swing-type inductor components with contoured core pieces and preformed winding clips creates non-uniform gaps to vary inductance values, allowing for higher inductance at lighter loads and lower inductance at full loads, enabling efficient operation at lower switching frequencies and maintaining constant current ripple.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional inductor components are miniaturized, then component size is reduced and component density is increased, but the ability to maintain constant current ripple and efficiency across varying load conditions deteriorates
Solution Approach 1:
The patent implements a swing-type inductor design where the inductance value dynamically changes with current load. The magnetic core operates at different saturation levels depending on current magnitude, automatically adjusting inductance to maintain constant current ripple across varying loads. This dynamic adaptation resolves the contradiction between miniaturization and performance stability.
Solution Approach 2:
The patent changes the inductance parameter as a function of current load. By designing the magnetic core to operate at partial saturation under high current and linear region under low current, the inductance value naturally varies to compensate for load changes, maintaining constant current ripple despite reduced component size.
2Adaptability or versatility
If swing-type inductor components are designed with contoured core pieces and preformed winding clips, then inductance variation capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs preformed winding clips that are manufactured separately and then assembled onto the core pieces. This preliminary preparation of components simplifies the final assembly process and reduces manufacturing complexity despite the contoured geometry of the core pieces. The winding clips are pre-shaped to match the contoured core surface, making assembly straightforward.
3Power
If inductor components operate at higher current loads, then power handling capability is improved, but magnetic saturation occurs causing inductance to drop
Solution Approach 1:
The swing-type inductor design embraces the magnetic saturation phenomenon rather than fighting it. The magnetic core is deliberately designed to operate in the saturation region under high current loads, where the inductance naturally decreases. This dynamic behavior is characteristic of swing chokes and is exploited to maintain constant current ripple in power supply applications.
Solution Approach 2:
The patent intentionally allows the inductance parameter to change with current load. Under high current, the magnetic core saturates and inductance decreases, which is the desired behavior for maintaining constant current ripple. This parameter change is a functional feature rather than a defect.
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 approach results in enhanced performance and cost-effective manufacturing of miniaturized inductor components that can efficiently handle high current and power demands with reduced size and increased component density.
Implementation Method 1
Current flow through a conductor in the inductor component generates a magnetic field
Implementation Method 2
The magnetic field can, in turn, be productively used to store energy in a magnetic core
Implementation Method 3
the second shaped magnetic core piece includes a stepped surface adjacent the channel, the stepped surface configured to establish a non-uniform gap between the first shaped magnetic core piece and the second shaped magnetic core piece
Implementation Method 4
the swing-type inductor component may include a core that can be operated almost at magnetic saturation under certain current loads
Data Source
AI summary
A surface mount swing-type inductor component is configured to establish a non-uniform gap when assembled. The non-uniform gap produces swing-type inductor functionality in a compact package for higher current applications while being manufacturable at relatively low cost.