Electrical inductor device

Patent metadata

Field	Value
Publication number	US-11610718-B2
Application number	US-201916579117-A
Country	US
Kind code	B2
Filing date	Sep 23, 2019
Priority date	Sep 23, 2019
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

Abstract

An inductor that is configured to store energy in a magnetic field includes a wire and a core. The wire is configured to deliver electrical current to the inductor to generate the magnetic field. The core is disposed radially about the wire. The core comprises magnetic particles that are suspended in a non-magnetic matrix. The magnetic particles are arranged such that a magnetic permeability of the core increases in a direction that extends radially outward from the wire along a cross-sectional area of the magnetic core from a first region that is adjacent to the wire to a second region that is adjacent to an outer periphery of the magnetic core.

First claim

What is claimed is:

1. An inductor configured to store energy in a magnetic field comprising:
a magnetic core defining a central orifice, the magnetic core comprising a magnetic powder suspended in a non-magnetic matrix, the magnetic powder having spherically-shaped particles and flake-shaped particles that are arranged such that a ratio of the flake-shaped particles to the spherically-shaped particles varies in a direction that extends radially outward from the central orifice along a cross-sectional area of the magnetic core from a first region that is adjacent to the central orifice to a second region that is adjacent to an outer periphery of the magnetic core and such that a magnetic permeability of the magnetic core varies in the direction that extends radially outward from the central orifice along the cross-sectional area, of the magnetic core; and
an electrical conductor disposed within the central orifice and configured to deliver electrical current to the inductor to generate the magnetic field.

2. The inductor of claim 1 , wherein each of the flake-shaped particles have a pair of substantially parallel and planar exterior surfaces that are separated by a thickness of the flake-shaped particles, and wherein the pair of substantially parallel and planar exterior surfaces of each flake-shaped particle are arranged to extend concentrically about the central orifice.

3. The inductor of claim 1 , wherein the magnetic core comprises a rolled sheet of material that is comprised of the magnetic powder suspended in the non-magnetic matrix.

4. The inductor of claim 1 , wherein the magnetic core and electrical conductor are collectively wound into a spiral such that the inductor is a spiral inductor.

5. The inductor of claim 1 , wherein the ratio varies from at most 2:1 to at least 100:1.

6. An inductor configured to store energy in a magnetic field comprising:
a wire configured to deliver electrical current to the inductor to generate the magnetic field; and
a core disposed radially about the wire, the core comprising magnetic particles suspended in a non-magnetic matrix, wherein the magnetic particles are arranged such that a magnetic permeability of the core increases in a direction that extends radially outward from the wire along a cross-sectional area of the core from a first region that is adjacent to the wire to a second region that is adjacent to an outer periphery of the core.

7. The inductor of claim 6 , wherein the magnetic particles comprise flake-shaped particles.

8. The inductor of claim 7 , wherein the core further comprises non-magnetic particles suspended in a non-magnetic matrix.

9. The inductor of claim 8 , wherein a ratio or the flake-shaped particles to the non-magnetic particles increases in a direction that extends radially outward from the wire along the cross-sectional area of the core.

10. The inductor of claim 9 , wherein the ratio increases from at most 2:1 within the first region to at least 4:1 within the second region.

11. The inductor of claim 7 , wherein each of the flake-shaped particles have a pair of substantially parallel and planar exterior surfaces that are separated by a thickness of the flake-shaped particles, and wherein the pair of substantially parallel and planar exterior surfaces of each flake-shaped particle are arranged to extend concentrically about the wire.

12. The inductor of claim 6 , wherein the magnetic particles comprise flake-shaped particles and spherically-shaped particles.

13. The inductor of claim 12 , wherein a ratio of the flake-shaped particles to the spherically-shaped particles increases in a direction that extends radially outward from the wire along the cross-sectional area of the core.

14. The inductor of claim 13 , wherein the ratio increases from at most 2:1 within the first region to at least 4:1 within the second region.

15. The inductor of claim 12 , wherein each of the flake-shaped particles have a pair of substantially parallel and planar exterior surfaces that are separated by a thickness of the flake-shaped particles, and wherein the pair of substantially parallel and planar exterior surfaces of each flake-shaped particle are arranged to extend concentrically about the wire.

16. The inductor of claim 6 , wherein the core and electrical conductor are collectively wound into a spiral such that the inductor is a spiral inductor.

17. The inductor of claim 6 , Wherein the core comprises a rolled sheet of material that is comprised of the magnetic powder suspended in the non-magnetic matrix.

Assignees

• Ford Global Tech Llc

Inventors

• Li Wanfeng
• Rong Chuanbing
• Degner Michael W

Classifications

• H01F27/255

  made from particles (H01F27/26 takes precedence) · CPC title

• H01F27/245 Primary

  made from sheets, e.g. grain-oriented (H01F27/26 takes precedence) · CPC title

• H01F41/0233

  Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16) · CPC title

• H01F17/04 Primary

  with magnetic core · CPC title

• H01F27/2823

  Wires (H01F27/2866 takes precedence) · CPC title