Wire-Wound Inductor Core Geometry for Magnetic Field Radiation
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Solution Overview
Problem
Existing wire-wound inductors face challenges in maximizing radiation efficiency of the magnetic field emitted from the upper flange, particularly when the side surface of the winding core extends vertically, as they tend to spread out in-plane directions, reducing the efficiency of magnetic field emission.
Innovation Solution
A wire-wound inductor design with a columnar winding core and terminal electrodes at the lower flange, where the wire is wound around the side surface, ensuring the cross-sectional area of the winding core is larger than the lateral area of the upper flange, thereby increasing the magnetic field emission from the upper flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the wire is wound around in multiple layers or a large-diameter wire is used to increase inductance and reduce direct current resistance, then the inductance increases and direct current resistance decreases, but the diameter of the winding core portion increases
Solution Approach 1:
The patent changes the geometric parameters of the inductor by setting specific relationships between the cross-sectional area Sa and lateral area Sb of the winding core portion, ensuring Sa/Sb ≥ 1. This parameter optimization allows achieving high inductance while maintaining a compact diameter by optimizing the shape and dimensions of the winding core rather than simply increasing wire diameter or layer count
2Ease of operation
If the side surface of the winding core portion extends in the up-down direction, then the inductor can be mounted on a circuit substrate, but the radiation efficiency of the magnetic field emitted from the upper flange decreases
Solution Approach 1:
The patent optimizes the geometric parameters by ensuring the cross-sectional area Sa is greater than or equal to the lateral area Sb (Sa/Sb ≥ 1). This parameter change directs more magnetic field lines upward through the upper flange rather than allowing them to spread in-plane, thereby improving radiation efficiency while maintaining the vertical extension configuration needed for substrate mounting
Solution Approach 2:
The patent creates different functional zones within the winding core portion by optimizing the relationship between cross-sectional area and lateral area. The larger cross-sectional area relative to lateral area concentrates magnetic flux density in the vertical direction, creating a local quality enhancement that directs magnetic field emission preferentially upward from the upper flange
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 enhances the radiation efficiency of the magnetic field emitted from the upper flange, reducing attenuation with distance and improving coupling coefficients between inductors, while maintaining a compact size and preventing wire breakage or short-circuiting.
Implementation Method 1
a magnetic field generated in the winding core portion by an electric current flowing in the wire
Data Source
AI summary
A wire-wound inductor includes a core that includes a columnar winding core portion having a side surface extending in an up-down direction, an upper flange disposed at an upper end of the winding core portion, and a lower flange disposed at a lower end of the winding core portion. The wire-wound inductor also includes a pair of terminal electrodes formed at the lower flange and a wire wound around the side surface of the winding core portion, the wire having both end portions coupled to respective terminal electrodes. In the wire-wound inductor, a ratio Sa/Sb of a cross-sectional area Sa to a lateral area Sb is one or more, where the cross-sectional area Sa is an area of cross section of the winding core portion and the lateral area Sb is an area of a side-surface extension portion that passes through the upper flange.