Coil Component With Alternating Conductor Layers
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Solution Overview
Problem
Existing coil components with α-winding coils embedded in composite materials face challenges in reducing size while maintaining low direct-current resistance, as the compression forming process makes it difficult to minimize direct-current resistance effectively.
Innovation Solution
A coil component design featuring a coil conductor with alternately stacked thin and thick conductor layers, covered with a glass layer, and embedded in an element assembly with a filler and resin material, where the conductor layers are electrically coupled to outer electrodes, allowing for reduced size and low direct-current resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separately formed α-winding coil is placed between composite material sheets and compression formed, then the coil component can be manufactured, but it is difficult to reduce the coil in size and sufficiently reduce direct-current resistance
Solution Approach 1:
The coil conductor is divided into multiple thin conductor layers (first conductor layers) and thick conductor layers (second conductor layers) that are alternately stacked. This segmentation allows the coil to achieve low direct-current resistance through the thick layers while maintaining compact size through the thin layers, resolving the contradiction between manufacturability and size reduction.
Solution Approach 2:
The coil conductor is constructed as a composite structure combining thin conductor layers and thick conductor layers in an alternating stacked pattern. This composite conductor design enables simultaneous achievement of small size and low direct-current resistance, which cannot be achieved with conventional single-structure coils.
2Ease of manufacture
If a separately formed α-winding coil is placed between composite material sheets and compression formed, then the coil component can be manufactured, but it is difficult to sufficiently reduce direct-current resistance
Solution Approach 1:
The coil conductor is segmented into alternating thin and thick conductor layers, where the thick layers (second conductor layers) provide low direct-current resistance paths while the thin layers (first conductor layers) maintain structural integrity. This segmentation resolves the contradiction between ease of manufacture and reduction of direct-current resistance.
Solution Approach 2:
The composite conductor structure with alternating thin and thick layers achieves sufficiently low direct-current resistance while maintaining manufacturability through the systematic alternating pattern, which is difficult to achieve with conventional uniformly thick coils.
3Reliability
If the coil conductor uses thick conductor layers to reduce direct-current resistance, then direct-current resistance decreases, but the coil component size increases
Solution Approach 1:
The coil conductor is segmented into alternating thin and thick layers, allowing the thick layers to reduce direct-current resistance while the thin layers minimize overall volume. This segmentation resolves the contradiction between reducing direct-current resistance and minimizing component size.
Solution Approach 2:
The composite structure of alternating thin and thick conductor layers achieves the dual benefit of low direct-current resistance from thick layers and compact size from thin layers, resolving the contradiction between these two parameters.
Data Source
AI summary
The present disclosure provides a coil component including an element assembly containing a filler and a resin material, a coil portion composed of a coil conductor embedded in the element assembly, and a pair of outer electrodes electrically coupled to the coil conductor. A relatively thin first conductor layer and a relatively thick second conductor layer are stacked in the coil conductor.