Coil Component with Laminated Soft Magnetic Core and Micro Gaps

Solution Overview

Problem

Existing coil components with metal magnetic plates experience increased core loss and temperature rise when used as inductors, limiting their effectiveness.

Innovation Solution

A coil component design featuring a magnetic core with laminated soft magnetic layers, micro gaps, and Fe-based nano-crystals, where the soft magnetic layers are divided into small pieces and arranged parallel to the magnetic flux direction, reducing core loss and enhancing inductance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a metal magnetic plate is used in the coil component, then inductance is improved, but core loss increases and temperature rises

Engineering Contradiction:

ImproveinductanceVSAvoidcore loss

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The soft magnetic layers are divided into multiple small pieces by forming micro gaps, which segments the continuous magnetic path. This segmentation reduces eddy current loops and thereby decreases core loss while maintaining sufficient inductance through proper arrangement of the segmented pieces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Micro gaps are formed in the soft magnetic layers, creating a porous-like structure with controlled void spaces. These micro gaps interrupt eddy current paths and reduce core loss, while the overall magnetic properties are maintained through the laminated structure and material composition

Inventive Principle:

Principle #31Porous materials

2Power

If a metal magnetic plate is used in the coil component, then inductance is improved, but temperature rises

Engineering Contradiction:

ImproveinductanceVSAvoidtemperature rise

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The soft magnetic layers are divided into multiple small pieces by forming micro gaps, which segments the continuous magnetic path. This segmentation reduces eddy current loops and thereby decreases core loss while maintaining sufficient inductance through proper arrangement of the segmented pieces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Micro gaps are formed in the soft magnetic layers, creating a porous-like structure with controlled void spaces. These micro gaps interrupt eddy current paths and reduce core loss, while the overall magnetic properties are maintained through the laminated structure and material composition

Inventive Principle:

Principle #31Porous materials

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 achieves high inductance while suppressing core loss and temperature rise, improving the performance of the coil component by controlling the number of small pieces per unit area and the thickness of the soft magnetic layers.

Implementation Method 1

a structure consisting of Fe-based nano-crystals is observed in the soft magnetic layers

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Implementation Method 2

micro gaps are formed in the soft magnetic layers, the soft magnetic layers are divided into at least two or more small pieces by the micro gaps

Methodology Applied

Scientific EffectEddy Currents: Eddy Currents

Data Source

PatentUS11682507B2Coil component

Publication Date: 2023.06.20 TDK CORP

AI summary

A coil component having high inductance while suppressing core loss is obtained. The coil component includes a coil and a magnetic core. The magnetic core has a laminated body in which soft magnetic layers are laminated. Micro gaps are formed in the soft magnetic layers. The soft magnetic layers are divided into at least two or more small pieces by the micro gaps. A structure made of Fe-based nano-crystals is observed in the soft magnetic layers.