Coil Component Magnetic Layer Segmentation for Short-Circuit Prevention
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Solution Overview
Problem
Existing coil components with substantially flat magnetic materials suffer from short-circuiting between outer electrodes and failed plating due to low specific electrical resistance, which affects their inductance and reliability.
Innovation Solution
A coil component design featuring a magnetic layer with substantially spherical metallic magnetic material on top and bottom, and substantially flat metallic magnetic material between these layers and the outer electrodes, preventing short-circuiting while improving inductance by optimizing the placement and orientation of magnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a substantially flat magnetic material is used to achieve higher magnetic permeability and higher inductance, then the inductance is improved, but the specific electrical resistance is low causing short-circuiting between outer electrodes and failed plating
Solution Approach 1:
The magnetic core is divided into multiple magnetic layers with different material characteristics. The first magnetic layer contains substantially spherical magnetic material with high specific electrical resistance to prevent short-circuiting, while the second magnetic layer contains substantially flat magnetic material with high magnetic permeability to improve inductance. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between reliability and performance.
Solution Approach 2:
Different regions of the magnetic core are assigned different material properties tailored to local requirements. The region closer to the outer electrodes (first magnetic layer) uses spherical material for electrical insulation, while the region surrounding the coil conductor (second magnetic layer) uses flat material for magnetic enhancement. This local differentiation optimizes both reliability and inductance without requiring a single complex material throughout.
2Reliability
If a substantially flat magnetic material is used, then the magnetic permeability and inductance are improved, but the specific electrical resistance is low causing harmful electrical conduction
Solution Approach 1:
The magnetic core is segmented into two distinct magnetic layers. The first magnetic layer uses substantially spherical magnetic material providing high specific electrical resistance for electrical insulation. The second magnetic layer uses substantially flat magnetic material providing high magnetic permeability. This segmentation enables electrical insulation without requiring the entire magnetic core to be made of spherical material, thus avoiding excessive material usage.
Solution Approach 2:
Spherical magnetic material is applied locally in the first magnetic layer where electrical insulation is most critical (near outer electrodes), while flat magnetic material is used in the second layer where magnetic performance is prioritized. This local application of different material types optimizes the balance between electrical insulation and magnetic performance while controlling material quantities.
3Reliability
If only spherical magnetic material is used to prevent short-circuiting, then electrical insulation is improved, but the magnetic permeability and inductance decrease
Solution Approach 1:
The magnetic core is divided into two functional layers: the first magnetic layer with spherical material provides electrical insulation resistance, while the second magnetic layer with flat material provides magnetic permeability enhancement. This segmentation ensures that each material type is used where it is most effective, preventing the trade-off between insulation and magnetic performance that would occur with a single-material approach.
Solution Approach 2:
The magnetic core employs a composite structure with two different magnetic material types in separate layers. The substantially spherical magnetic material in the first layer contributes high specific electrical resistance, while the substantially flat magnetic material in the second layer contributes high magnetic permeability. This composite approach allows the system to simultaneously achieve both electrical insulation and magnetic performance enhancement.
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 effectively prevents short-circuiting and failed plating, enhancing the inductance of the coil component by utilizing the higher specific electrical resistance of spherical magnetic material and the higher magnetic permeability of flat material, thus improving both performance and reliability.
Implementation Method 1
a substantially flat metallic magnetic material having a flattening of about 0.50 or more. The substantially flat soft magnetic metallic material is oriented in the direction of the coil axis
Implementation Method 2
a low specific electrical resistance of the magnetic layer made with a substantially flat magnetic material can cause short-circuiting between the outer electrodes
Data Source
AI summary
A coil component includes a body, a coil conductor embedded in the body, and outer electrodes disposed on the outside of the body. The body includes a first magnetic layer containing a substantially spherical metallic magnetic material and second and third layers containing a substantially flat metallic magnetic material. At least the wound section of the coil conductor is between the second and third magnetic layers in the direction along the axis of the coil conductor. In the direction perpendicular to the axis, the second and third magnetic layers have a width equal to or larger than the outer diameter of the wound section of the coil component. The substantially flat metallic magnetic material is oriented so that the flat plane thereof is perpendicular to the axis of the coil conductor. The first magnetic layer extends between the second and third magnetic layers and the outer electrodes.