Coil Component Low Permeability Part Design
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Solution Overview
Problem
In coil components, especially those with magnetic metal grains, it is challenging to maintain high magnetic permeability while minimizing magnetic flux leakage, which leads to increased copper losses and reduced inductance values due to eddy currents and flux leakage near low magnetic permeability parts.
Innovation Solution
A coil component design featuring an element body part with magnetic metal grains and nonmagnetic materials, where a low magnetic permeability part is strategically positioned between the coil's surfaces to limit magnetic flux leakage, maintaining high inductance values and reducing copper losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low magnetic permeability part is provided inside the element body part to improve direct-current superimposition properties, then direct-current superimposition properties are improved, but magnetic flux leaks into the conductor causing eddy current and copper losses
Solution Approach 1:
The patent applies local quality by providing a low magnetic permeability part only in specific regions (outer regions) of the element body part, while maintaining high magnetic permeability in other regions. This localized differentiation allows the low magnetic permeability part to improve direct-current superimposition properties without causing excessive magnetic flux leakage that would lead to eddy current and copper losses in the conductor.
Solution Approach 2:
The patent changes the magnetic permeability parameter spatially within the element body part by incorporating a low magnetic permeability part with relative permeability of 1.05 to 1.05 times that of the main part. This parameter modification in specific regions improves direct-current superimposition properties while controlling magnetic flux leakage to prevent excessive copper losses.
2Reliability
If the element body part is formed by material containing magnetic metal grains, then insulation property is achieved, but it is difficult to increase magnetic permeability to sufficiently high level resulting in large leakage of magnetic flux
Solution Approach 1:
The patent applies local quality by introducing a low magnetic permeability part in outer regions of the element body part formed with magnetic metal grains. This localized structure compensates for the inherently limited magnetic permeability of magnetic metal grain materials, reducing magnetic flux leakage without compromising the insulation properties provided by the magnetic metal grain structure.
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 keeps losses low while maintaining inductance values by strategically placing low magnetic permeability parts within the coil component, reducing eddy currents and flux leakage, thus improving direct-current superimposition properties and reducing copper losses.
Implementation Method 1
a large leakage of magnetic flux occurs near the low magnetic permeability part. As magnetic flux leaks into the conductor constituting the coil, eddy current will generate in the conductor
Implementation Method 2
As magnetic flux leaks into the conductor constituting the coil, eddy current will generate in the conductor and copper losses will occur
Data Source
AI summary
In an exemplary embodiment, a coil component includes: an element body part 10 that contains magnetic metal grains and nonmagnetic materials and has insulation property; and a coil 30 embedded in the element body part 10 and formed by a winding conductor. The element body part 10 has a main part 11 and a low magnetic permeability part 50 whose relative permeability is lower than that of the main part 11; the coil 30 has a first surface 36 and a second surface 38 respectively representing surfaces positioned on opposite sides in the direction of the coil axis and intersecting the coil axis; and the low magnetic permeability part 50 is provided between a first plane 37 flush with the first surface 36, and a second plane 39 flush with the second surface 38, in a manner away from the first plane 37 and the second plane 39.