Coil Component Inductance via Electrode Extension
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Solution Overview
Problem
Existing coil components with metal magnetic substrates are prone to dielectric breakdown when subjected to high voltage due to lower dielectric strength compared to ferrite substrates, and reducing the winding part's outer diameter to prevent breakdown results in lower inductance, making it difficult to achieve desired inductance values, especially in smaller designs.
Innovation Solution
The coil component features a winding part embedded in a substrate with metal magnetic grains, where the winding is strategically placed in specific regions and wound by one turn or more, with lead parts extending orthogonally to increase inductance while maintaining a sufficient spacing to prevent dielectric breakdown, allowing for a larger winding diameter and higher inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding part's outer diameter is reduced to prevent dielectric breakdown in metal magnetic grain substrates, then dielectric breakdown is prevented, but inductance decreases
Solution Approach 1:
The patent extends the external electrodes from the conventional configuration (only on end faces) to include extension along the lateral surfaces of the substrate. This dimensional extension allows the electrodes to be positioned farther from the winding part, increasing the spacing without reducing the winding diameter, thus preventing dielectric breakdown while maintaining inductance
Solution Approach 2:
The substrate is divided into distinct regions: a first region containing the winding part, and second regions containing the extended external electrodes. This segmentation allows the winding part to maintain its diameter for sufficient inductance while the electrodes are positioned in separate regions at greater distances, preventing dielectric breakdown
2Reliability
If the winding part's outer diameter is reduced to prevent dielectric breakdown, then dielectric breakdown is prevented, but the desired inductance value cannot be achieved
Solution Approach 1:
By extending external electrodes along the lateral surfaces of the substrate in addition to the end faces, the patent creates additional spatial dimension for electrode placement. This allows maintaining larger winding diameter for desired inductance while achieving sufficient electrode-winding spacing for high voltage resistance
Solution Approach 2:
The patent uses a substrate containing metal magnetic grains combined with strategically positioned external electrodes that extend along multiple surfaces. This composite structure provides both the magnetic properties needed for inductance and the spatial distribution needed for dielectric breakdown prevention
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 prevents dielectric breakdown and increases inductance, enabling the achievement of desired inductance values while ensuring the coil component's reliability under high-voltage conditions.
Implementation Method 1
a coil having a winding part constituted by a wound conductor
Implementation Method 2
a substrate body formed in a manner containing metal magnetic grains
Data Source
AI summary
A coil component includes: a coil embedded in a substrate body and having a winding part constituted by a wound conductor; wherein the substrate body has: a first region sandwiched between one end surface of the substrate body and a plane parallel with the one end surface and running through a portion of a first external electrode farthest away from the one end surface; a second region sandwiched between another end of the substrate body and a plane parallel with the another end surface and running through a portion of a second external electrode farthest away from the another end surface; and a third region between the first region and the second region; and the winding part is provided in the third region, and also in the first region where it is wound by one turn or more.