Coil Component Insulation Layer and Magnetic Body Volume
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Solution Overview
Problem
The existing coil components suffer from insufficient creepage distance between adjacent coil patterns, leading to potential short circuits due to inadequate insulation, which compromises both insulating properties and coil characteristics.
Innovation Solution
A coil component design featuring a flat coil pattern on an insulation substrate with a resin wall that defines the coil region, an insulation layer covering the coil pattern, and a magnetic body that integrates with the substrate and fills the space between resin walls, enhancing insulation and increasing the magnetic body's volume to improve coil characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin wall is used to define the coil region, then the coil pattern is properly formed and protected, but the creepage distance between adjacent coil patterns becomes insufficient leading to potential short circuits
Solution Approach 1:
The invention extends the insulation solution from a two-dimensional planar separation (resin wall between coils) to a three-dimensional structure by adding an insulation layer that covers the upper surface of the coil pattern. This multi-dimensional approach to insulation ensures that both the side surfaces (via resin wall) and the upper surface (via insulation layer) are protected, effectively increasing the creepage distance without increasing the planar footprint.
Solution Approach 2:
The insulation layer is positioned on top of the coil pattern, nested within the space defined by the resin wall structure. The magnetic body then encapsulates both the coil pattern and the insulation layer, creating a nested configuration where each layer provides additional insulation functionality. This nested arrangement maximizes the use of available space to achieve sufficient creepage distance.
2Reliability
If the magnetic body volume is increased to improve coil characteristics, then inductance and other performance metrics improve, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The magnetic body is segmented into two functional regions: a first magnetic body that fills the space between adjacent resin walls ( providing lateral support and magnetic functionality), and a second magnetic body that covers the upper surface of the insulation layer (providing additional magnetic path and increasing effective magnetic volume). This segmentation allows the magnetic body to achieve increased volume and improved coil characteristics while maintaining a structured, manufacturable form that follows the modular layout of the underlying components.
Data Source
AI summary
In a coil component, an insulation layer covers an upper surface of a conductor pattern. Accordingly, insulating properties between the conductor pattern and a magnetic body are enhanced, and insulating properties between the conductor patterns are enhanced. In addition, in the coil component, the magnetic body enters a space between resin walls such that the insulation layer is covered. Therefore, a volume of the magnetic body above the conductor pattern is increased, and high coil characteristics are realized.