Thin-Film Inductor Layout for High Inductance and Saturation Current
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Solution Overview
Problem
Conventional thin film inductors face challenges in increasing inductance value without increasing size, leading to manufacturing difficulties and reduced saturation current due to increased turns in the spiral coil.
Innovation Solution
A thin film inductor design with a first substrate having a non-circuit layout, where electrically conductive circuits are arranged around the layout, and magnetic layers are embedded in the substrate, allowing for adjustable properties and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of turns of the spiral coil is increased to increase inductance value, then the inductance value is improved, but the manufacturing difficulty increases and saturation current is reduced
Solution Approach 1:
The patent divides the single spiral coil structure into multiple separate coil assemblies, each with fewer turns. These coil assemblies are arranged in a matrix pattern on the substrate, with each assembly contributing to the overall inductance. This segmentation allows for easier manufacturing of individual coils while achieving the required total inductance through the combined effect of multiple coils.
Solution Approach 2:
The patent transitions from a conventional single-plane spiral coil to a three-dimensional arrangement of multiple coil assemblies on the substrate surface. By utilizing the two-dimensional substrate area more efficiently and stacking magnetic layers, the design achieves higher inductance without increasing the complexity of individual coil structures, thereby improving manufacturability.
2Reliability
If the number of turns of the spiral coil is increased to increase inductance value, then the inductance value is improved, but the saturation current is reduced
Solution Approach 1:
By dividing the total inductance requirement across multiple coil assemblies with fewer turns each, the current distribution is optimized. Each individual coil operates at lower current density, delaying the onset of magnetic saturation and effectively increasing the overall saturation current capability while maintaining the required inductance value.
Solution Approach 2:
The patent changes the magnetic path parameters by introducing multiple magnetic layers and optimizing the magnetic core structure. This allows for higher magnetic flux capacity, increasing the saturation current threshold. The magnetic layer configuration and material selection are adjusted to achieve the desired balance between inductance and saturation current.
3Area of stationary object
If the size of the thin film inductor is reduced to meet smaller electronic products, then the size is improved, but the inductance value becomes difficult to maintain
Solution Approach 1:
The patent utilizes vertical stacking of magnetic layers to increase inductance density. By arranging multiple magnetic layers at different heights and configuring multiple coil assemblies on the substrate, the design achieves higher inductance values within a compact footprint, effectively utilizing the third dimension to overcome the size constraint.
Solution Approach 2:
The patent employs composite magnetic layer structures with different magnetic permeability characteristics. By combining materials and layer configurations that optimize magnetic flux distribution, the design achieves high inductance values in a reduced area. The composite structure allows for tailored magnetic properties that maximize inductance density.
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 design reduces manufacturing difficulty and allows for flexible adjustment of inductor properties while maintaining high saturation current and inductance value.
Implementation Method 1
When an electric current passes through the spiral coil, a magnetic flux change occurs at in the central part surrounded by the spiral coil, such that the coil assembly that includes the spiral coil generates an induction current
Data Source
AI summary
A thin film inductor is provided. The thin film inductor includes a first coil assembly, a first magnetic layer, and a second magnetic layer. The first coil assembly includes a first substrate and two first electrically conductive circuits respectively arranged on two surfaces of the first substrate that are opposite to each other. The first magnetic layer and the second magnetic layer are respectively arranged on the two surfaces of the first substrate that are opposite to each other, and the two first electrically conductive circuits are respectively embedded in the first magnetic layer and the second magnetic layer. The first substrate has a first non-circuit layout, and the first electrically conductive circuit is arranged around the first non-circuit layout. A ratio between an area of the first non-circuit layout and an area of the first substrate is 0.1 or more.