Coil Component Impedance Control via Insulation Layer Thickness
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Solution Overview
Problem
Existing common mode choke coils face challenges in adjusting impedance values due to limitations in adjusting the number of turns and magnetic permeability, making it difficult to achieve precise impedance settings, which is time-consuming and costly.
Innovation Solution
The solution involves forming an insulation layer for impedance adjustment on a magnetic substrate, allowing for precise thickness control using thin film techniques, and alternately stacking coil patterns with insulation layers, with exposed regions filled with a resin containing magnetic powder to bond a second magnetic substrate, enabling easy adjustment of impedance values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of turns and length of conductor are adjusted to achieve predetermined impedance value, then the impedance can be controlled, but it is difficult to adjust due to limitations in external electrode position and chip shape
Solution Approach 1:
The patent changes the parameter being adjusted from conductor geometry (number of turns, length) to insulation layer thickness. By making the insulation layer thickness the adjustable parameter instead of conductor dimensions, the impedance can be controlled without being constrained by electrode position limitations or chip shape restrictions.
Solution Approach 2:
The patent separates the impedance control function from the conductor structure by introducing a dedicated insulation layer for impedance adjustment. This segmentation allows independent optimization of conductor geometry and impedance characteristics, with the insulation layer serving as a separate adjustment mechanism.
2Manufacturing precision
If the permeability of magnetic material is adjusted to achieve predetermined impedance value, then the impedance can be controlled, but it is quite difficult to adjust the permeability minutely
Solution Approach 1:
The patent replaces magnetic material permeability adjustment with insulation layer thickness adjustment. This parameter substitution enables precise impedance control through a more controllable parameter (film thickness) rather than requiring minute adjustments to magnetic permeability.
Solution Approach 2:
The patent introduces the insulation layer as an intermediary element between the magnetic substrate and the coil conductor. This intermediary provides a new degree of freedom for impedance control, decoupling the impedance adjustment from direct modifications to the magnetic material properties.
3Manufacturing precision
If various conditions are changed and examined one by one to adjust impedance value, then the impedance can be optimized, but it results in heavy burden in terms of both time and cost
Solution Approach 1:
The patent identifies insulation layer thickness as the primary control parameter for impedance, eliminating the need to systematically vary multiple parameters (conductor turns, conductor length, magnetic permeability). This single-parameter control dramatically reduces the number of iterations required for optimization.
Solution Approach 2:
The patent performs impedance adjustment during the manufacturing process by controlling the insulation layer thickness from the outset, rather than requiring post-manufacturing adjustments or iterative testing of multiple design variations.
4Manufacturing precision
If thin film forming techniques are used for the insulation layer for impedance value adjustment, then the impedance value can be achieved accurately with small variation
Solution Approach 1:
The patent replaces mechanical adjustment methods (physical modification of conductor or magnetic material) with thin film forming techniques (deposition processes). This substitution enables precise thickness control through controlled deposition, achieving accurate impedance values with small variations.
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 method allows for accurate and efficient adjustment of impedance values with minimal variation, reducing the time and cost associated with achieving desired impedance settings in common mode choke coils.
Implementation Method 1
a resin including magnetic powder provided on the uppermost insulation layer and the insulation-layer-removed regions
Data Source
AI summary
There is provided a method of manufacturing a coil component, where a first insulation layer is formed on a first magnetic substrate, an insulation film is formed on the first insulation layer, a coil conductor is formed on the insulation film, another insulation film is formed on the coil conductor, and an open region is formed on the inner circumference side and on the outer circumference side of the coil conductor. A magnetic later is embedded, at least partially, in the open region, and a second magnetic substrate is secured on the magnetic layer. Also, a plurality of electrode terminals are formed, where one of the electrode terminals is connected to a terminal portion of the coil conductor, and the electrode terminals are provided across sides of the first and second magnetic substrates. Therefore, the first insulation layer can suitably prevent shorting failures between the electrode terminals.