Coil Component Gap Structure for DC-Bias Control
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Solution Overview
Problem
Existing coil components face challenges in adjusting DC-bias characteristics and reducing flux saturation velocity without altering the material properties of magnetic powders, particularly in thin-film inductors used in electronic devices.
Innovation Solution
A coil component design featuring a support substrate with a coil portion, a magnetic body, a nonmagnetic layer below a through-portion, and an insulating layer between the nonmagnetic layer and the through-portion, which increases the magnetic resistance and adjusts DC-bias characteristics by introducing a gap structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the material properties of magnetic powder are changed to adjust DC-bias characteristics, then DC-bias characteristics are improved, but the complexity of material selection and manufacturing process increases
Solution Approach 1:
The magnetic body is divided into multiple magnetic layers with different saturation magnetization values. Each layer contributes differently to the overall magnetic properties, allowing DC-bias characteristics to be adjusted by controlling the thickness ratio of layers rather than changing material composition. This segmentation approach simplifies manufacturing while achieving the desired magnetic characteristics.
Solution Approach 2:
Instead of changing material properties, the invention changes structural parameters - specifically the thickness ratios of magnetic layers with different saturation magnetization values. By adjusting these geometric parameters, the equivalent DC-bias characteristics are tuned without requiring complex material selection or property modification.
2Speed
If resistance of the component is increased to decrease flux saturation velocity, then flux saturation velocity is reduced, but the component loses efficiency in energy transmission
Solution Approach 1:
The magnetic body consists of layers with different local magnetic properties - specifically different saturation magnetization values. This local quality variation allows different regions to contribute differently to flux saturation behavior, effectively controlling flux saturation velocity without uniformly increasing resistance across the entire component, thus preserving energy transmission efficiency.
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 design effectively decreases flux saturation velocity and implements target DC-bias characteristics without changing the material of the body, enhancing the performance of the coil component.
Implementation Method 1
increases the magnetic resistance and adjusts DC-bias characteristics by introducing a gap structure
Implementation Method 2
a coil portion disposed on at least one surface of the support substrate
Data Source
AI summary
A coil component includes a support substrate, a coil portion disposed on at least one surface of the support substrate, a magnetic body, in which the support substrate and the coil portion are disposed, having a through-portion penetrating through a center of the coil portion, a nonmagnetic layer disposed below the through-portion, and an insulating layer disposed between the nonmagnetic layer and the through-portion.