Inductor with variable permeability core

Abstract

An inductor includes a magnetic core composed of a magnetic material having variable permeability characteristics based on at least one of design parameters or operational parameters of the inductor that includes one or more air gaps. A coil is wound through the one or more air gaps and is configured to be excited by an electric current.

1 . An inductor comprising:
 a magnetic core composed of a magnetic material having variable permeability characteristics based on at least one of design parameters or operational parameters of the inductor that includes one or more air gaps; and   a coil wound through the one or more air gaps configured to be excited by an electric current.   
     
     
         2 . The inductor of  claim 1 , wherein the inductor is a planar inductor. 
     
     
         3 . The inductor of  claim 1 , wherein the design parameters include at least one of dimensions of the magnetic core, shape of the magnetic core, positions of the one or more air gaps on the magnetic core, size of the one or more air gaps, or material properties of the magnetic core. 
     
     
         4 . The inductor of  claim 1 , wherein the operational parameters include at least one of an inductance, direct current (DC) bias, flux density characteristics, or core loss characteristics of the inductor. 
     
     
         5 . The inductor of  claim 1 , wherein the variable permeability characteristics of the magnetic core correspond to an amount of permeability nonlinearity wherein a permeability for a predetermined amount of flux density is greater than a predetermined threshold. 
     
     
         6 . The inductor of  claim 1 , wherein the variable permeability characteristics of the magnetic core correspond to a flux density saturation area of the magnetic core that is less than a predetermined threshold. 
     
     
         7 . The inductor of  claim 1 , wherein the variable permeability characteristics of the magnetic core correspond to a core loss density in the magnetic core that is less than a predetermined threshold. 
     
     
         8 . The inductor of  claim 1 , wherein a shape of the one or more air gaps in the magnetic core correspond to a predetermined flux density pattern across the magnetic core. 
     
     
         9 . The inductor of  claim 8 , wherein the shape of the one or more air gaps is an oval shape. 
     
     
         10 . The inductor of  claim 1 , wherein the magnetic core is a single structure produced using a binder matrix with magnetic filler material via three-dimensional (3D) printing. 
     
     
         11 . The inductor of  claim 1 , wherein the magnetic core is composed of a heterogeneous ferrite material having a plurality of densities throughout the magnetic core. 
     
     
         12 . The inductor of  claim 11 , wherein each of the plurality of densities throughout the magnetic core correspond to a ratio of the ferrite material to air at one or more locations throughout the magnetic core, wherein the ratio of the ferrite material to air is based on the variable permeability characteristics. 
     
     
         13 . The inductor of  claim 1 , wherein the magnetic core is composed of a homogenous ferrite material having a plurality of slits, wherein the plurality of slits are configured at predetermined locations and orientations throughout the magnetic core based on the variable permeability characteristics. 
     
     
         14 . The inductor of  claim 1 , wherein the magnetic core is composed of a heterogeneous ferrite material having
 a first ferrite material with a first density at one or more first locations within the magnetic core, and   a second ferrite material with a second density at one or more second locations within the magnetic core,   wherein the first density and the second density are based on a ratio of the ferrite material to air.   
     
     
         15 . The inductor of  claim 14 , wherein the first density of the first ferrite material is greater than the second density of the second ferrite material. 
     
     
         16 . The inductor of  claim 14 , wherein the magnetic core includes a plurality of slits configured at predetermined locations and orientations throughout the magnetic core based on the variable permeability characteristics. 
     
     
         17 . The inductor of  claim 14 , wherein the one or more first locations of the first ferrite material and the one or more second locations of the second ferrite material are based on the variable permeability characteristics. 
     
     
         18 . The inductor of  claim 1 , further comprising:
 a plurality of stacked magnetic cores composed of a magnetic material having variable permeability characteristics based on at least one of the design parameters or the operational parameters of the inductor.   
     
     
         19 . A method comprising:
 determining design parameters for an inductor including at least one of dimensions of a magnetic core, shape of the magnetic core, positions of one or more air gaps on the magnetic core, size of the one or more air gaps, or material properties of the magnetic core;   determining operational parameters for the inductor including at least one of an inductance, DC bias, flux density characteristics, or core loss characteristics; and   providing a magnetic core composed of a magnetic material having variable permeability characteristics based on at least one of the design parameters or the operational parameters of the inductor that includes one or more air gaps.   
     
     
         20 . A magnetic core for an inductor comprising:
 a magnetic material having variable permeability characteristics based on at least one of design parameters or operational parameters of the inductor that includes one or more air gaps, wherein   the one or more air gaps are configured to receive a coil wound through the one or more air gaps configured to be excited by an electric current.