Common Mode Choke Coil Magnetic Substrate Cutout Design
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Solution Overview
Problem
Conventional common mode choke coils face difficulties in achieving sufficient impedance due to the inability of magnetic flux to pass through contact holes, resulting in inadequate inductance values.
Innovation Solution
The design incorporates a magnetic substrate with cutout portions and a multilayer body with overlapping corners, featuring coils and external electrodes, along with connecting portions positioned to avoid interrupting the magnetic flux, thereby enhancing impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional contact hole structure is used for electrical connection, then manufacturing is simplified, but impedance is insufficient due to inadequate inductance
Solution Approach 1:
The magnetic substrate is segmented into regions with different magnetic flux passing characteristics. The connecting portions are placed in non-magnetic flux passing portions, maintaining manufacturing simplicity while ensuring magnetic flux passes through dedicated paths to achieve sufficient inductance and impedance.
Solution Approach 2:
The magnetic substrate acts as an intermediary element that simultaneously supports both electrical connection (through connecting portions in non-magnetic flux passing portions) and magnetic flux conduction (through magnetic flux passing portions). This intermediary structure resolves the contradiction by mediating between electrical and magnetic requirements.
2Reliability
If magnetic flux path is maintained for high inductance, then impedance is improved, but component size may increase
Solution Approach 1:
The magnetic substrate has different local properties: magnetic flux passing portions for inductance and non-magnetic flux passing portions for compact electrical connections. This allows efficient use of space where magnetic flux paths are concentrated in specific regions, preventing unnecessary expansion while maintaining high impedance.
Solution Approach 2:
The patent utilizes the z-axis (stacking direction) to route magnetic flux through the multilayer body, allowing inductance to be achieved in the vertical dimension rather than requiring large horizontal areas. This dimensional approach resolves the contradiction by achieving high impedance without increasing planar footprint.
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 enables a common mode choke coil with increased inductance values and impedance, improving noise removal performance in high-frequency ranges while allowing for a reduced component size.
Implementation Method 1
a first coil provided in the multilayer body, the first coil including a first coil portion and a first lead portion which is connected with one end of the first coil portion and which is drawn out to the first corner; a second coil which is provided in the multilayer body and which is combined with the first coil to constitute a common mode choke coil, the second coil including a second coil portion which is magnetically coupled with the first coil portion
Data Source
AI summary
A magnetic substrate has such a shape that ridges extending between principal surfaces are cut away by cutout portions. A multilayer body has corners arranged so as to overlap the cutout portions. A coil includes lead portions which are connected with both ends of a coil portion and which are drawn out to the corners. A coil is combined with the coil to constitute a common mode choke coil and includes lead portions which are connected with both ends of a coil portion and which are drawn out to the corners. Connecting portions connect external electrodes to the lead portions and are provided at the cutout portion.