Coil Component with Dual Permeability Magnetic Layers
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Solution Overview
Problem
Miniaturized and thinned coil electronic components face challenges in maintaining magnetic characteristics and efficiency due to limitations in increasing the magnetic material ratio, and there is a need to adjust the coupling coefficient of coupled inductors for various applications without increasing the mounting area.
Innovation Solution
A coil electronic component with a coupled inductor structure featuring first and second coil portions magnetically coupled by an intermediate layer with different magnetic particle volume fractions and permeabilities, and an encapsulant with distinct magnetic particles, allowing for adjustable coupling inductance between coil portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ratio of magnetic material in the core is increased to maintain magnetic characteristics during miniaturization, then magnetic performance is improved, but the strength of the inductor body deteriorates and frequency characteristics vary due to insulating property limitations
Solution Approach 1:
The patent employs composite magnetic materials with different permeabilities arranged in specific patterns (series and parallel configurations) to achieve the desired magnetic characteristics without requiring a simple increase in magnetic material ratio. This allows optimization of both magnetic performance and mechanical strength through material composition design.
Solution Approach 2:
The patent applies local quality by creating regions with different magnetic permeabilities within the core structure. By strategically placing magnetic materials with varying permeability values in specific locations, the design achieves uniform magnetic characteristics while maintaining structural integrity and avoiding the need to uniformly increase magnetic material throughout the entire core.
2Productivity
If the coupling coefficient of a coupled inductor is increased to reduce inductor current ripple, then efficiency is improved, but the leakage inductance changes and output current ripple characteristics deteriorate
Solution Approach 1:
The patent utilizes parameter changes by adjusting the permeability values of different magnetic material regions and their geometric arrangements to independently control coupling inductance and leakage inductance. This allows optimization of the coupling coefficient to reduce current ripple while maintaining appropriate leakage inductance levels for output current ripple control.
Solution Approach 2:
The patent segments the magnetic core into multiple regions with different permeability characteristics (first magnetic material and second magnetic material with different permeabilities). This segmentation enables independent control of mutual inductance and leakage inductance, allowing the coupling coefficient to be optimized for efficiency while maintaining proper leakage inductance for output current ripple characteristics.
3Area of stationary object
If the size of the inductor array chip is reduced to decrease mounting area, then space utilization is improved, but the efficiency of the inductor array deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the permeability values and geometric dimensions of the magnetic materials to achieve high coupling coefficients in a compact footprint. This allows the inductor array to maintain high efficiency with reduced current ripple while occupying minimal mounting area.
Solution Approach 2:
The patent uses composite magnetic material structures with varying permeabilities to achieve enhanced magnetic coupling in a reduced space. The strategic arrangement of high and low permeability materials allows efficient magnetic flux linkage between coils while maintaining compact dimensions for reduced mounting 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
This configuration effectively adjusts the coupling coefficient of the coil electronic component, enhancing efficiency by controlling mutual and leakage inductance while maintaining the component's size and reducing the mounting area, thereby addressing the limitations of existing technologies.
Implementation Method 1
first and second coil portions magnetically coupled to each other
Implementation Method 2
The intermediate layer and the encapsulant have permeabilities different from each other
Data Source
AI summary
A coil electronic component includes first and second coil portions magnetically coupled to each other, an intermediate layer disposed between the first and second coil portions and including first magnetic particles, and an encapsulant encapsulating the first and second coil portions and including second magnetic particles. The intermediate layer and the encapsulant have permeabilities different from each other.