Wire-Wound Power Inductor Core Segmentation for Permeability
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Solution Overview
Problem
Existing wire-wound type power inductors face challenges in achieving high permeability due to the complexity of stacking plate-shaped magnetic powder flakes, which can lead to non-uniformity and difficulty in aligning magnetic fields effectively.
Innovation Solution
A wire-wound type inductor core is designed with a bonding structure of first and second bodies, where magnetic powder flakes with shape magnetic anisotropy are arranged such that their long axes are parallel to the magnetic field direction, enhancing magnetic flux concentration and inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plate-shaped magnetic powder flakes are stacked to achieve high permeability, then magnetic performance is improved, but manufacturing complexity increases and uniformity cannot be secured
Solution Approach 1:
The core is divided into a first body and a second body that are bonded together. Each body contains magnetic powder flakes with aligned long axes, creating segmented structures that are easier to manufacture while maintaining high permeability through the bonding interface
Solution Approach 2:
Magnetic powder flakes are pre-aligned in a specific direction during the formation of each body before the bonding process. This preliminary alignment ensures uniform magnetic properties without requiring complex post-assembly adjustments or stacking operations
2Reliability
If plate-shaped magnetic powder flakes are used with shape magnetic anisotropy, then magnetic field concentration is improved, but alignment uniformity deteriorates due to stacking difficulties
Solution Approach 1:
Each body (first and second bodies) is designed with locally optimized magnetic powder flake alignment in the direction of the magnetic field. The bonding structure ensures that this local alignment quality is maintained across the entire core, achieving uniform magnetic properties without complex stacking
Solution Approach 2:
The core uses composite structures of first and second bodies bonded together, where each body contains magnetic powder flakes with specific orientation. This composite approach maintains the shape magnetic anisotropy benefits while improving alignment uniformity through the bonding interface design
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 improves the permeability and structural reliability of the inductor by stabilizing the alignment of magnetic powder flakes, allowing for efficient magnetic flux concentration and increased inductance.
Implementation Method 1
the magnetic powder flakes contained in the first and second bodies may magnetic powder flakes having shape magnetic anisotropy, and long axes of the magnetic powder flakes may be arranged in parallel in a direction in which a magnetic field of the winding coil is formed
Data Source
AI summary
A wire-wound type inductor includes a core containing magnetic powder flakes and including a central portion and an outside portion, and a winding coil disposed in the core and wound around the central portion of the core, wherein the core has a coupling structure including first and second bodies, and the first and second bodies contain magnetic powder flakes having shape magnetic anisotropy, and long axes of the magnetic powder flakes are arranged in parallel with a direction in which a magnetic field of the winding coil is formed.