Coil Electronic Component Magnetic Flux Control
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Solution Overview
Problem
Thin film type inductors face challenges in maintaining high performance and reliability while minimizing thickness, as they tend to experience decreased inductance at high currents and compromised DC bias characteristics due to saturation magnetic flux density limitations.
Innovation Solution
A coil electronic component design featuring a substrate with a coil pattern and a magnetic flux controlling part having a higher saturation magnetic flux density than the body region, which covers the coil pattern to minimize inductance decrease and improve DC bias characteristics by strategically adjusting the magnetic flux saturation levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of the coil electronic component is decreased to meet slimness requirements, then the component becomes thinner and more compact, but the inductance decreases significantly at high currents due to magnetic flux saturation
Solution Approach 1:
The patent applies local quality by using two different magnetic materials with different saturation magnetic flux densities in different regions. The first magnetic material with lower saturation magnetic flux density is placed in the core region where magnetic flux concentration is highest, while the second magnetic material with higher saturation magnetic flux density is placed in the surrounding region. This local differentiation allows the component to maintain thin profile while preventing saturation-induced inductance decrease at high currents.
Solution Approach 2:
The patent uses composite materials by combining two different magnetic materials in a single component structure. The body region contains a magnetic material with specific saturation magnetic flux density, while the surrounding region contains a different magnetic material with higher saturation magnetic flux density. This composite approach enables the thin film component to achieve both compact size and stable inductance characteristics under high current conditions.
2Ease of manufacture
If a single magnetic material is used in the entire coil structure, then the manufacturing process is simplified, but the DC bias characteristics and inductance stability at high current are compromised
Solution Approach 1:
The patent implements local quality by differentiating the magnetic material properties in different regions. The core region uses one magnetic material optimized for basic inductance, while the surrounding region uses another magnetic material with higher saturation magnetic flux density specifically to improve DC bias characteristics. This regional differentiation resolves the contradiction by maintaining reasonable manufacturing complexity while achieving superior electrical performance.
3Reliability
If the saturation magnetic flux density of the magnetic material is increased to maintain inductance at high current, then the inductance stability improves, but the component thickness cannot be reduced further
Solution Approach 1:
The patent resolves this contradiction by applying local quality - placing the high saturation magnetic flux density material specifically in the surrounding region where it is most needed for preventing saturation, while keeping the core region material thinner. This spatial optimization allows the component to achieve both thin profile and stable inductance at high current.
Solution Approach 2:
The patent uses composite materials with different saturation magnetic flux densities arranged in specific regions. The combination of a thinner core material with a surrounding high-density material allows the overall component to be thinner while maintaining the inductance stability that would otherwise require uniformly thick high-density material throughout.
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 maintains inductance values at high currents while enhancing DC bias characteristics by using a magnetic flux controlling part with a saturation magnetic flux density of 140 emu/g or more, ensuring reliable performance in thin film type inductors.
Implementation Method 1
a magnetic flux controlling part covering at least the coil pattern and having a material having a saturation magnetic flux density higher than that of a magnetic material contained in the body region
Data Source
AI summary
A coil electronic component includes a substrate; a coil pattern formed on at least one of first and second main surfaces of the substrate; a body region filling at least a core region of the coil pattern and having a magnetic material; and a magnetic flux controlling part covering at least the coil pattern and having a material having a saturation magnetic flux density higher than that of a magnetic material contained in the body region.