Coil Component Flat Filler Orientation
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Solution Overview
Problem
Conventional coil components with exterior bodies containing filler particles face limitations in increasing effective magnetic permeability due to peeling issues caused by thermal stress and adhesive forces, restricting the content ratio of filler particles.
Innovation Solution
The coil component incorporates filler particles with shape anisotropy, oriented parallel to the winding core axis, within the exterior portion, aligning the magnetic flux and easy magnetization direction to enhance magnetic permeability without increasing the filler particle content ratio, thereby reducing thermal stress and peeling risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the content ratio of filler particles in the exterior body is increased to increase effective magnetic permeability, then the effective magnetic permeability is improved, but the exterior body is likely to peel off from the drum core due to low adhesive force and thermal stress
Solution Approach 1:
The patent changes the shape parameter of filler particles from spherical to flat, creating shape anisotropy. This parameter change allows the particles to provide magnetic permeability enhancement while their flat geometry enables better stress distribution and adhesion to the drum core, resolving the contradiction between increasing filler content ratio and maintaining peeling resistance
Solution Approach 2:
The patent creates a composite exterior body structure consisting of resin and flat-shaped filler particles with specific orientation. This composite material approach allows optimization of both magnetic properties and mechanical adhesion by controlling the shape and arrangement of filler particles within the resin matrix, enabling high effective magnetic permeability without compromising structural integrity
2Quantity of substance
If the content ratio of filler particles is increased to achieve high inductance with reduced wiring turns, then the effective magnetic permeability is improved, but stress from filler particles on resin increases causing peeling
Solution Approach 1:
The patent changes the geometric parameter of filler particles to flat shapes with defined orientation parallel to the drum core axis. This parameter change reduces thermal stress concentration on the resin matrix while maintaining high effective magnetic permeability, thereby preventing peeling even with increased filler particle content ratio
Solution Approach 2:
The patent applies local quality by orienting flat-shaped filler particles in a specific direction (parallel to the drum core axis) rather than random distribution. This localized orientation arrangement optimizes the magnetic flux path and reduces stress concentration in critical areas, allowing higher filler content without increasing stress on the resin
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 effective magnetic permeability while minimizing peeling and stress, achieving higher performance with reduced filler particle content and suppressing eddy currents, leading to a more stable and efficient coil component.
Implementation Method 1
the exterior portion has an easy magnetization direction oriented parallel to an axis of the winding core
Implementation Method 2
In order to increase an effective magnetic permeability of the coil component, the exterior body may possibly be formed by using a resin into which filler particles such as of a ferrite powder are mixed
Implementation Method 3
since said filler particles have an adhesive force extremely low compared with that of said resin, it becomes likely that said exterior body is peeled off from a drum core
Implementation Method 4
when the resin in the exterior body is thermally cured, the filler particles do not thermally shrink (the resin in the exterior body has a linear expansion coefficient significantly larger than that of the filler particles), so that stress is exerted from said filler particles on said resin
Data Source
AI summary
One object is to provide a new improvement for increasing an effective magnetic permeability of a coil component. A coil component according to one embodiment of the present invention includes a drum core having a first flange, a second flange, and a winding core coupling said first flange to said second flange, a winding wire wound on the winding core, and an exterior portion provided around the winding core so as to cover at least part of the winding wire. Said exterior portion has an easy magnetization direction oriented parallel to an axis of the winding core.