Coil Component Magnetic Cover Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components with closed magnetic circuits suffer from magnetic saturation, which impairs DC bias characteristics while attempting to maintain good inductance characteristics.
Innovation Solution
A coil component design featuring a core with winding core portions and flanges, where a magnetic cover portion and a non-magnetic cover portion are strategically arranged to prevent magnetic contact and saturation, allowing magnetic flux to pass through an open circuit, thereby enhancing DC bias characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a closed magnetic circuit configuration is used with cladding resin containing magnetic powder, then inductance characteristics are improved by keeping leakage flux small, but magnetic saturation occurs impairing DC bias characteristics
Solution Approach 1:
The cover portion is divided into two distinct segments: a first cover portion containing magnetic powder for reducing leakage flux, and a second cover portion made of non-magnetic material for preventing magnetic saturation. This segmentation allows each portion to perform its specific function without the adverse effects of a fully closed magnetic circuit.
Solution Approach 2:
Different regions of the cover portion are assigned different magnetic properties: the first cover portion has magnetic characteristics to reduce leakage flux in critical areas, while the second cover portion has non-magnetic characteristics to prevent saturation. This local differentiation resolves the contradiction between reducing leakage and preventing saturation.
2Measurement precision
If resin composition containing magnetic material is applied to cover the winding, then inductance characteristics are enhanced, but the resin may adhere to flange faces forming a closed magnetic circuit that impairs DC bias characteristics
Solution Approach 1:
The second cover portion made of non-magnetic material is applied to the flange faces before the magnetic resin composition is applied. This preliminary action creates a barrier that prevents the magnetic resin from adhering to the flange faces, thereby preventing the formation of a closed magnetic circuit while still allowing the magnetic resin to enhance inductance characteristics in the winding area.
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 effectively reduces magnetic saturation and enhances DC bias characteristics while maintaining good inductance by ensuring the magnetic flux passes through an open circuit, preventing resin adhesion and maintaining desired inductance values.
Implementation Method 1
the magnetic flux generated in the coil formed by the winding passes thus through the first cover portion between the first and second flanges. This keeps hence leakage flux small
Implementation Method 2
the second cover portion is interposed at least between the first flange and the first cover portion, whereby the first flange and the first cover portion do not come into contact with each other. In consequence, a magnetic gap is formed by the second cover portion
Data Source
AI summary
A coil component comprises: a core having a winding core portion, and a first flange and a second flange arranged at both ends of the winding core portion; a winding arranged in a region flanked by the first and second flanges, and wound so as to be in contact with the winding core portion; and a cover portion arranged in a region flanked by the first and second flanges, so as to cover the winding. The cover portion has a first cover portion comprising a resin cured product containing a magnetic material; and a second cover portion comprising a non-magnetic material. The second cover portion is interposed at least between the first flange and the first cover portion.