Coil Component Bridge Conductor Layer DC Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing common mode filters face challenges in reducing direct-current resistance and manufacturing costs due to increased electrostatic capacity and complex manufacturing processes when attempting to widen coil conductors for improved electrical characteristics.
Innovation Solution
A coil component design featuring a bridge conductor layer between two coil conductor layers with insulation films, where the thickness of lead-out conductors is greater than the bridge conductors, and the bridge conductors are not exposed on side surfaces, allowing for a reduced distance between coil conductors without increasing manufacturing steps or using different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil conductors are formed with a greater width to decrease direct-current resistance and improve electrical characteristics, then the direct-current resistance decreases and electrical characteristics improve, but a greater electrostatic capacity is generated between the two coil conductors
Solution Approach 1:
The patent introduces a bridge conductor layer positioned between the first and second coil conductor layers, creating a three-dimensional spatial arrangement. This dimensional change allows the coil conductors to be wider for lower DC resistance while the bridge conductor maintains adequate spacing to control electrostatic capacity, resolving the contradiction by utilizing vertical layering rather than only horizontal spacing.
Solution Approach 2:
The bridge conductor layer acts as an intermediary structure between the two coil conductor layers. It provides electrical connection between inner circumferential ends of the coil conductors while maintaining physical separation, thus enabling wider coil conductors without excessive electrostatic capacity between them.
2Object-generated harmful factors
If the thickness of the insulator layer between the two coil conductors is increased to suppress increase in electrostatic capacity, then the electrostatic capacity decreases, but the number of manufacturing steps increases and manufacturing cost increases
Solution Approach 1:
The patent combines the insulator layer formation with the bridge conductor formation into a single integrated process. The bridge conductor is formed on the insulator layer in the same manufacturing sequence, eliminating the need for separate insulator layer formation steps and reducing overall manufacturing complexity and cost.
Solution Approach 2:
The insulator layer serves multiple functions simultaneously: it provides electrical insulation between coil conductor layers, supports the bridge conductor structure, and maintains the required spacing between coil conductors to control electrostatic capacity. This multi-functionality reduces the need for additional dedicated structures or steps.
3Object-generated harmful factors
If the distance between the two coil conductors is increased to suppress increase in electrostatic capacity, then the electrostatic capacity decreases, but the direct-current resistance increases
Solution Approach 1:
The patent resolves this contradiction by transitioning from two-dimensional horizontal spacing to three-dimensional vertical arrangement. The coil conductors can be wide in the horizontal plane for low DC resistance, while the bridge conductor layer in the vertical dimension maintains appropriate spacing to control electrostatic capacity, allowing both requirements to be satisfied simultaneously.
Data Source
AI summary
The invention relates to surface-mount type coil components having a mounting surface for mounting them on a printed circuit board or hybrid IC (HIC) and provides a low-cost coil component having a low direct-current resistance. A common mode filter includes a bridge conductor layer which has a bridge conductor one end of which is connected to one end of a lead wire and another end of which is connected to an inner circumferential end of a coil conductor and another bridge conductor one end of which is connected to one end of another lead wire and another end of which is connected to an inner circumferential end of another coil conductor, the bridge conductor layer being formed between two coil conductor layers with an insulation film interposed between the bridge conductor layer and each of the coil conductor layers.