Systems using multi-layer-multi-turn high efficiency inductors
A multi-layer, multi-turn structure for an inductor having a plurality of conductor layers separated by layers of insulator is described. The inductor further comprises a connector electrically connected between the conductor layers. The structure of the inductor may comprise a cavity therewithin. The structure of the inductor constructed such that electrical resistance is reduced therewithin, thus increasing the efficiency of the inductor. The inductor is particularly useful at operating within the radio frequency range and greater.
1. An electrical system, comprising:
a) an electrical power source;
b) a control circuit electrically connected to the electrical power source;
c) a first circuit electrically connected to the control circuit, the first circuit comprising an inductor, comprising:
i) a first conductor layer;
ii) a second conductor layer spaced apart from the first conductor layer, the first conductor layer and the second conductor layer being electrically conductive;
iii) an insulator layer positioned in the space between the first conductor layer and the second conductor layer; and
d) wherein when an electrical current, supplied by the electrical power source, is propagated within at least the first conductor layer a magnetic flux is generated within the inductor; and
e) wherein when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current causes an inductance to be generated.
2. The electrical system of claim 1 wherein an electromotive force is generated when at least one of the frequency, the magnitude, or the waveform shape is changed.
3. The electrical system of claim 1 wherein a magnitude of the magnetic flux is proportional to the amount of change of at least one of the frequency, the magnitude, or the waveform shape of the electrical current.
4. The electrical system of claim 1 wherein, an electrical resistance of at least one of the first conductor layer or the second conductor layer is reducable when a cross-sectional area of a conducting skin depth within at least the first conductor layer or the second conductor layer is increased, wherein the increased cross-sectional area is a result of electrically connecting at least a third conductor layer to the second conductor layer, a second insulator layer positioned therebetween.
5. The electrical system of claim 1 wherein a thickness of the first conductor layer is about equal to a thickness of a skin depth of the first conductor layer at a given frequency.
6. The electrical system of claim 1 wherein a thickness of the first conductor ranges from about 1.25 times to about 4 times a thickness of a skin depth of the first conductor layer at a given frequency.
7. The electrical system of claim 1 wherein a thickness of the second conductor ranges from about 1.25 times to about 4 times a thickness of a skin depth of the second conductor layer at a given frequency.
8. The electrical system of claim 1 wherein a first conductor layer thickness is about the same as a second conductor layer thickness.
9. The electrical system of claim 1 wherein a first conductor layer thickness is different from a second conductor layer thickness.
10. The electrical system of claim 1 wherein a thickness of a first skin depth of the first conductor layer is about the same as a thickness of a second skin depth of the second conductor layer.
11. The electrical system of claim 1 wherein a thickness of a first skin depth of the first conductor layer is different than a thickness of a second skin depth of the second conductor layer.
12. The electrical system of claim 1 wherein a thickness of the insulating layer is less than about 5 cm.
13. The electrical system of claim 1 wherein the inductor has an inductor quality factor greater than about 5.
14. The electrical system of claim 13 wherein the inductor quality factor is defined by the equation
Q
=
2
π
fL
R
where f is the frequency of operation, L is the inductance, and R is the total ohmic and radiative resistance.
15. The electrical system of claim 1 wherein the inductor is capable of operating at an inductor frequency of at least 3 kHz.
16. The electrical system of claim 1 wherein at least one of the first and second conductor layers is formed from a thermally conductive material.
17. The electrical system of claim 1 wherein at least one connector electrically connects the first conductor layer and the second conductor layer electrically in parallel or series.
18. The electrical system of claim 17 wherein the connector is selected from the group consisting of a via, a solder, a tab, a wire, a pin, a rivet, a filled mesh structure, a conductive polymer, a conductive composite, a conductive adhesive, a liquid metal, a foamed metal, and combinations thereof.
19. The electrical system of claim 1 wherein the first conductor layer and the second conductor layer form a structure in which the first and second conductor layers are positioned in about a parallel orientation, a perpendicular, or at an angular relationship therebetween.
20. The electrical system of claim 1 comprising a third conductor layer and a fourth conductor layer electrically connected in parallel wherein the first and second conductive layers are connected electrically in parallel and are further connected electrically in series with the third and fourth conductor layer.
21. The electrical system of claim 1 wherein the inductor is electrically connectable with a second electrical circuit operating at about 100 kHz or greater.
22. The electrical system of claim 21 wherein the first electrical circuit is selected from the group consisting of a mixer circuit, an impedance matching circuit, an upconverting mixer circuit, a downconverting mixer circuit, a modulator, a demodulator, a synthesizing circuit, a PLL synthesizing circuit, an amplifying circuit, an electrical driver circuit, an electrical detecting circuit, an RF log detector, an RF RMS detector, an electrical transceiver, a power controller, and combinations thereof.
23. The electrical system of claim 1 wherein the inductor is electrically connectable within an induction heating circuit.
24. The electrical system of claim 1 wherein a second control circuit is electrically connectable to the inductor.
25. The electrical system of claim 1 wherein at least the first and second conductor layers has at least a partial revolution.
26. The electrical system of claim 1 wherein the first conductor layer or the second conductor layer comprises a material selected from the group consisting of copper, titanium, platinum, platinum and iridium alloys, tantalum, niobium, zirconium, hafnium, nitinol, cobalt-chromium-nickel alloys, stainless steel, gold, a gold alloy, palladium, carbon, silver, a noble metal, a conductive polymer, a conductive adhesive, a conductive composite, a liquid metal, a foamed metal, a conductive tape, a conductive ribbon, a conductive foil, a conductive leaf, a wire, a deposited metal, a biocompatible material, and combinations thereof.
27. The electrical system of claim 1 wherein at least one insulator layer is formed from an electrically insulative material.
28. The electrical system of claim 1 wherein the insulator layer comprises an electrically insulative material selected from the group consisting of air, polystyrene, silicon dioxide, a biocompatible ceramic, a conductive dielectric material, a non-conductive dielectric material, a piezoelectric material, a pyroelectric material, a ferrite material, and combinations thereof.
29. The electrical system of claim 1 wherein the system is capable of operating at an electrical circuit frequency of at least 3 kHz.
30. The electrical system of claim 1 wherein a microprocessor electronically controls the control circuit.
31. The electrical system of claim 1 wherein the system is operatable at an electrical circuit frequency or frequencies of at least 10 MHz.
32. An electrical system, comprising:
a) an electrical power source;
b) a control circuit electrically connected to the electrical power source;
c) a first circuit electrically connected to the control circuit, the first circuit comprising a first inductor, comprising:
i) a first conductor layer and a second conductor layer spaced apart from the first conductor layer, the first conductor layer and the second conductor layer being electrically conductive;
ii) a first insulator layer positioned in the space between the first conductor layer and the second conductor layers;
iii) a first connector electrically connecting the first conductor layer and the second conductor layer electrically in parallel;
d) a second inductor electrically connected to the control circuit, the second inductor comprising:
i) a third conductor layer and a fourth conductor layer spaced apart from the third conductor layer, the third conductor layer and the fourth conductor layer being electrically conductive;
ii) a second insulator layer positioned in the space between the third conductor layer and the fourth conductor layers; and
iii) a second connector electrically connecting the third conductor layer and the fourth conductor layer electrically in parallel, wherein the first inductor is electrically connected in series or parallel to the second inductor;
e) wherein when an electrical current, supplied by the electrical power source, is propagated within at least the first conductor layer, a magnetic flux is generated within the first inductor and/or the second inductor; and
f) wherein when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current causes an inductance to be generated within the first inductor and/or the second inductor.
33. The inductor of claim 32 wherein the first conductor and the second inductor are oriented so that the first and second inductors are positioned about parallel, about perpendicular, or at an angular relationship therebetween.