Asymmetric Coil Component Layout for Compact Inductance Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coil components face a trade-off between compact size and inductance, where reducing the size to make them more compact can deteriorate inductance, and increasing the distance between the coil conductor and the base body to improve inductance results in a larger overall size.
Innovation Solution
A coil component design with a coil conductor that has a greater distance between first conductor portions and one surface than between second conductor portions and an opposing surface, allowing for a more compact size while maintaining adequate inductance by optimizing the magnetic flux path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the overall size of the base body is reduced to make the coil component more compact, then the size is reduced, but a sufficiently large region cannot be left between the coil conductor and the side surfaces to allow magnetic flux lines to pass through, which deteriorates the inductance
Solution Approach 1:
The patent applies asymmetry by positioning the coil conductor closer to one side surface of the base body than to the opposite side surface. Specifically, the distance between the coil conductor and the first side surface is made smaller than the distance between the coil conductor and the second side surface. This asymmetric arrangement allows the magnetic flux lines to have sufficient space to pass through the base body while maintaining a compact overall size, thereby resolving the contradiction between compactness and inductance.
2Reliability
If the distance between the coil conductor and the side surfaces of the base body is increased to improve the inductance, then the inductance is improved, but the overall size of the base body increases
Solution Approach 1:
The patent resolves this contradiction by implementing an asymmetric configuration where the coil conductor is positioned at unequal distances from the two side surfaces. By making the distance to one side surface smaller and the distance to the opposite side surface larger, the design provides adequate space for magnetic flux lines to pass through (improving inductance) while keeping the overall component size compact.
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
The design achieves a more compact coil component without deteriorating inductance, allowing for improved magnetic saturation characteristics and reduced size compared to conventional designs.
Implementation Method 1
a coil conductor arranged in the magnetic base body and extending around a coil axis... the winding portion has a plurality of first conductor portions and one or more second conductor portions smaller in number than the first conductor portions, and the first and second conductor portions alternate with and are connected to each other
Data Source
AI summary
A method for manufacturing a coil component comprises: forming a coil conductor including a winding portion, the winding portion including a plurality of first conductor portions and one or more second conductor portions smaller in number than the first conductor portions, the first and second conductor portions alternate with and connected to each other; forming a molded body by molding composite magnetic material including metal magnetic particles and a binder with the coil conductor being disposed inside the composite magnetic material; and heating the molded body to produce a magnetic base body. The magnetic base body is formed such that a distance between the first conductor portions and a first surface of the magnetic body is greater than a distance between the second conductor portions and a second surface of the magnetic base body opposite to the first surface, by molding, cutting or polishing.