Coil Component Insulating Layers Dielectric Breakdown
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-performance electronic components require stable driving characteristics and high reliability, especially in high-current environments, but existing coil components face issues with dielectric breakdown due to inadequate insulating properties between external electrodes and the body.
Innovation Solution
A coil component design featuring a support member with through-holes and via holes, internal coils on both surfaces of the support member, and insulating layers extending between the coils and external electrodes, with an encapsulant filling the gaps, enhancing electrical conductivity and reducing dielectric breakdown paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating layers are added between external electrodes and the body, then reliability is improved by suppressing dielectric breakdown paths, but device complexity increases due to additional insulating structures
Solution Approach 1:
The insulating layers are formed in advance during the manufacturing process, extending from the external electrodes toward the internal coils before final assembly. This preliminary action ensures that dielectric breakdown paths are suppressed from the outset, improving reliability without requiring additional post-assembly modifications.
Solution Approach 2:
The insulating layers extend in the thickness direction of the body, creating a three-dimensional insulating structure that blocks dielectric breakdown paths. By utilizing the thickness dimension, the patent effectively suppresses breakdown without adding lateral complexity to the device structure.
2Reliability
If the contact area between internal coils and external electrodes is increased, then reliability is improved by reducing dielectric breakdown likelihood, but manufacturing precision requirements increase
Solution Approach 1:
The contact structure is segmented into multiple regions: the internal coils are divided into first and second coils on opposite surfaces, and the external electrodes are correspondingly positioned. This segmentation allows each coil-electrode pair to have optimized contact area without requiring the entire structure to meet stringent precision requirements simultaneously.
Solution Approach 2:
The insulating layers serve as intermediaries that extend between the external electrodes and internal coils, providing a controlled interface. This intermediary structure facilitates increased contact area while maintaining manufacturing feasibility by defining clear boundaries and spacing requirements.
3Reliability
If insulating properties between external electrodes and body are improved, then dielectric breakdown is suppressed, but ease of manufacture decreases due to additional insulating layer processes
Solution Approach 1:
The insulating layers are merged with the existing support member structure, forming an integrated body that combines mechanical support and electrical insulation functions. This merging reduces the need for separate insulating components and simplifies the manufacturing process while maintaining improved insulating properties.
Solution Approach 2:
The body is formed as a composite structure combining the support member and insulating layers, where the insulating layers are integrated into the support member matrix. This composite approach achieves superior insulating properties without requiring separate manufacturing steps for distinct insulating components.
Data Source
AI summary
A coil component includes a body and external electrodes. The body includes a support member having through-openings formed in end portions thereof, an internal coil supported by the support member, and an encapsulant encapsulating the support member and the internal coil. The through-openings are filled with end portions of the internal coil. An insulating layer is interposed between the internal coil and the external electrode.