Coil Array Component Glass Insulation for Size Reduction
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Solution Overview
Problem
Existing coil array components face challenges in ensuring sufficient insulation when size reduction is necessary or when metal magnetic materials are used, leading to inadequate insulation performance.
Innovation Solution
A coil array component design that includes a filler and a resin material with a glass layer covering the coil conductors, a ferrite layer between the coils, and a specific manufacturing method using photolithography to form the coil and glass layers, which enhances insulation and supports size reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If size reduction is performed or metal magnetic material is used, then compactness is improved, but insulation performance deteriorates
Solution Approach 1:
A glass layer is introduced as an intermediary insulating material between the primary coil conductor and secondary coil conductor. This glass layer provides reliable insulation even when the overall component size is reduced or when metal magnetic materials are used, resolving the contradiction between compactness and insulation performance.
Solution Approach 2:
The coil array component uses a composite structure combining glass material as the insulating layer with metal magnetic materials. This composite approach allows the component to achieve both small size and high insulation performance by leveraging the complementary properties of different materials.
2Reliability
If insulating material is used between coils, then insulation performance is improved, but device complexity increases
Solution Approach 1:
The glass layer serving as an insulating material is integrated directly into the element assembly structure, merging the insulation function with the structural support function. This reduces device complexity by combining multiple functions into a single unified structure rather than adding separate insulating components.
Solution Approach 2:
The glass layer performs multiple functions simultaneously: it provides electrical insulation between coils, serves as a structural element of the element assembly, and supports the coil conductors. This multi-functionality reduces overall device complexity by eliminating the need for separate components.
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 improved insulation performance and size reduction while maintaining excellent electric characteristics, enabling efficient and compact coil array components.
Implementation Method 1
the first coil conductor and the second coil conductor are covered with a glass layer
Implementation Method 2
forming a conductor paste layer of a photosensitive metal paste containing a metal that constitutes the first coil conductor or the second coil conductor by using a photolithography method on a substrate
Implementation Method 3
forming the first coil portion and the second coil portion on the substrate by firing the substrate provided with the conductor paste layer, the glass paste layer, and the shape-retaining paste layer
Data Source
AI summary
A coil array component including an element assembly that includes a filler and a resin material, a first coil portion and a second coil portion that are embedded in the element assembly and that are composed of a first coil conductor and a second coil conductor, respectively, and four outer electrodes electrically connected to the first coil portion and the second coil portion. Also, the first coil conductor and the second coil conductor are covered with a glass layer.