Coil Component Core Body Tapering for Eddy-Current Loss Reduction
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Solution Overview
Problem
Existing coil components experience reduced Q-value due to eddy-current loss caused by interference between the wire and magnetic flux, primarily because the core body's constant thickness disrupts the magnetic flux lines, leading to inefficiencies in inductance and copper loss.
Innovation Solution
The coil component design features a core body with a peripheral face that tapers inwardly towards the center, aligning with magnetic flux lines, and incorporates inclined portions and a horizontal portion to ensure the wire conforms to these lines, reducing interference and eddy-current loss, while a resin member with oblique sides minimizes stray capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core body has a constant thickness, then the manufacturing is simple, but the wire interferes with the magnetic flux causing eddy-current loss and reduced Q-value
Solution Approach 1:
The core body thickness is varied locally - thinner at the center and thicker at the ends - to match the local density of magnetic flux lines. This local quality change allows the wire winding to follow the magnetic flux distribution, reducing eddy-current loss in the high-flux central region while maintaining structural integrity at the ends.
Solution Approach 2:
The core body thickness parameter is changed from a constant value to a variable value that decreases toward the center. This parameter change optimizes the magnetic flux distribution and reduces interference with the wire, thereby reducing eddy-current loss and improving the Q-value.
2Loss of energy
If the core body thickness varies to reduce eddy-current loss, then the Q-value increases, but the manufacturing complexity increases
Solution Approach 1:
The core body employs asymmetric thickness distribution - thinner at the center and thicker at the ends - which is optimized for magnetic flux concentration. This asymmetric design reduces eddy-current loss by allowing the wire to follow magnetic flux lines more closely, accepting increased manufacturing complexity as a trade-off for improved performance.
3Power
If the coil component size is increased, then the inductance increases, but the perimeter length and copper loss increase
Solution Approach 1:
The core body cross-sectional shape is changed from a conventional form to one with varying thickness in the radial direction (another dimension). This dimensional change allows the wire winding to follow the magnetic flux distribution more closely, increasing inductance efficiency without proportionally increasing the perimeter length and copper loss.
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 increases the Q-value by reducing eddy-current loss and maintaining inductance, allowing for a larger coil component size without increasing perimeter lengths, and further enhances Q-value through optimized resin member design to minimize stray capacitance.
Implementation Method 1
the shape of the peripheral face of the core body conforms to the lines of magnetic flux
Implementation Method 2
a wire wound around the core body and electrically connected to the first outer electrode and to the second outer electrode
Implementation Method 3
an eddy-current loss due to the interference with the magnetic flux may occur
Data Source
AI summary
A coil component includes a core including a core body, first and second flanges at first and second ends, respectively, of the body; first and second outer electrodes on the first and second flanges, respectively; and a wire wound around the body and electrically connected to the electrodes. The body has a peripheral face extending in a peripheral direction about an axis of the body. In a section containing the axis, a distance between at least a part of the face and the axis is smaller on a side near a center of the body in a direction of the axis than on a side near each of the first and second ends while a distance between the wire and the axis is smaller on the side near the center in the direction of the axis than on the side near each of the first and second ends.