Coil Component with Convex-Concave Magnetic Body for Heat Dissipation
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Solution Overview
Problem
The increasing demand for compact, high-performance power inductors in smartphones and IC chips poses challenges due to heat generation from coil resistance and magnetic material losses, which can lead to insulator damage, short circuits, and decreased magnetic properties.
Innovation Solution
A coil component with an embedded internal coil and a magnetic body having non-flat surfaces, where the thickness at the central axis is less than at a point spaced apart, enhancing heat radiation by increasing surface contact area and reducing volume, while maintaining inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power inductor is miniaturized to reduce length and width, then the size is reduced, but the heat radiation capability deteriorates
Solution Approach 1:
The patent transitions from two-dimensional flat surfaces to three-dimensional convex and concave structures on the magnetic body surfaces. By creating protrusions and recesses in multiple directions, the effective surface area for heat radiation is significantly increased without increasing the overall footprint dimensions, thus improving heat dissipation in miniaturized devices.
Solution Approach 2:
The patent employs curved convex and concave surfaces instead of flat planes on the magnetic body. These curved geometries increase the surface area-to-volume ratio, providing enhanced heat radiation capability while maintaining compact dimensions. The spherical and cylindrical elements contribute to more efficient thermal dissipation.
2Length of stationary object
If the thickness of the magnetic body is reduced to achieve low profile, then the profile is lowered, but the heat radiation efficiency deteriorates
Solution Approach 1:
Instead of increasing thickness to improve heat radiation, the patent adds dimensional complexity through convex and concave structures on the existing thin profile. This multi-directional surface modulation increases the effective heat radiation area without compromising the low-profile requirement.
Solution Approach 2:
The patent creates nested convex and concave structures where protrusions and recesses are arranged in overlapping patterns. This nesting approach maximizes surface area within the constrained thickness, allowing heat to radiate from multiple levels and surfaces simultaneously.
3Ease of manufacture
If conventional flat surfaces are used on the magnetic body, then the manufacturing is simple, but the heat radiation function is insufficient
Solution Approach 1:
The convex and concave surfaces can be formed using standard ceramic molding and sintering processes. The curved geometries are integrated into the mold design, allowing the magnetic body to be manufactured in a single firing cycle without complex post-processing, thus maintaining ease of manufacture while improving heat radiation.
Solution Approach 2:
The patent modifies surface geometry parameters (convex/concave dimensions, spacing, depth) to optimize heat radiation while maintaining compatibility with existing manufacturing processes. These parameter changes are implemented within the standard tolerances of ceramic component fabrication.
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 solution effectively radiates heat, improving the reliability and efficiency of power inductors by maintaining inductance and increasing the current rating (Irms) under elevated temperatures.
Implementation Method 1
heat radiation of the power inductor should be improved
Data Source
AI summary
A coil component includes: an internal coil; a magnetic body having the internal coil embedded therein, and having first and second surfaces opposing each other in a first direction, third and fourth surfaces opposing each other in a second direction, and fifth and sixth surfaces opposing each other in a third direction; and external electrodes connected to the internal coil and disposed on outer surfaces of the magnetic body. 0<T1/T2<1, where T1 is a thickness of the magnetic body at a central axis of the internal coil, and T2 is a thickness of the magnetic body at a point B positioned to be spaced apart from the central axis of the internal coil by a predetermined distance.