Coil Component Exposed Windings for DC Bias
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Miniaturization of inductor components limits the securement of a sufficient internal core area, leading to deteriorated direct current (DC) bias characteristics due to magnetic flux saturation, as the coil width is reduced and the turn of coils increases without adequate consideration for the core area, resulting in decreased inductance.
Innovation Solution
The coil portions are exposed to the outside of the body, removing the margin portion to secure a larger core area, with insulating layers applied to the exposed coil portions to enhance inductance and prevent exposure, allowing for improved DC bias characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil width is reduced to achieve miniaturization, then the size of the inductor component is reduced, but the core area becomes insufficient leading to magnetic flux saturation and deteriorated DC bias characteristics
Solution Approach 1:
The patent extends the core area in the width direction by exposing coil portions to the outside of the body, effectively utilizing the lateral dimension to increase the magnetic path area without increasing the overall volume of the component, thereby resolving the contradiction between miniaturization and sufficient core area
Solution Approach 2:
The patent embeds insulating layers within the body structure at the exposed coil portions, nesting the insulation function within the existing component geometry to prevent short circuits while maintaining the exposed configuration that increases effective core area
2Power
If the turn of coils is increased to maintain inductance in miniaturized components, then the coil density increases, but the core area becomes insufficient leading to magnetic flux saturation
Solution Approach 1:
By exposing coil portions to the outside surface of the body, the patent extends the magnetic path in the width direction, increasing the effective core area available for magnetic flux without increasing the number of coil turns, thus maintaining inductance while avoiding flux saturation
3Reliability
If coil portions are exposed to the outside of the body to increase core area, then DC bias characteristics are improved, but the risk of short circuits between coil portions increases
Solution Approach 1:
The patent introduces insulating layers as intermediary materials between the exposed coil portions and the body, preventing direct contact and potential short circuits while allowing the coil portions to remain exposed for increased core area and improved DC bias characteristics
Solution Approach 2:
The insulating layers are nested within the body structure at the exposed coil portions, integrating the insulation function into the component geometry itself, protecting against short circuits while maintaining the exposed configuration
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 significantly improves DC bias characteristics by increasing the core area, resulting in a 35% enhancement in DC bias performance compared to traditional designs, while maintaining miniaturization and high inductance.
Implementation Method 1
insulating layers disposed on the exposed coil portions
Data Source
AI summary
A coil component includes: a body having coil portions disposed therein and exposed to one or more of surfaces of the body opposing each other in a width direction; external electrodes disposed on external surfaces of the body and connected to the coil portions; and insulating layers further disposed on the exposed coil portions.