Indented Magnetic Particle Coil Component for Miniaturized Inductors
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Solution Overview
Problem
The miniaturization and thinning of coil components in electronic devices pose challenges in maintaining magnetic characteristics, as increasing the magnetic material ratio is limited by changes in inductor strength and frequency characteristics, particularly due to insulation properties.
Innovation Solution
A coil component with a body containing magnetic metal particles featuring indentations on their surfaces, which are spherical in shape and have different sizes and shapes, and are made from an Fe-based alloy with a high Fe content, improving magnetic permeability and packing factor by removing surface crystal grains and oxides through etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ratio of magnetic material in the core is increased to maintain magnetic characteristics during miniaturization and thinning, then magnetic permeability is improved, but the strength of the inductor body deteriorates
Solution Approach 1:
The patent changes the physical and chemical parameters of the magnetic metal particles by forming indentations on their surfaces. This modification allows the particles to pack more efficiently (increasing packing factor) and improves magnetic permeability without needing to increase the overall magnetic material ratio in the core, thereby maintaining body strength while achieving improved magnetic characteristics.
Solution Approach 2:
The patent applies local quality by creating indentations only on specific regions of the magnetic metal particle surfaces rather than changing the entire particle structure. This localized modification optimizes packing behavior and magnetic properties at the particle level while maintaining the overall structural integrity of the inductor body.
2Ease of manufacture
If conventional magnetic particles without surface modifications are used, then manufacturing is simpler, but packing factor of magnetic particles is lower resulting in reduced magnetic permeability
Solution Approach 1:
The patent changes the surface morphology parameter of magnetic particles by forming indentations, which significantly improves packing factor and magnetic permeability. The manufacturing process for creating these indentations (such as mechanical attrition or chemical etching) is relatively simple and can be integrated into existing production lines.
3Volume of moving object
If the component is miniaturized and thinned to meet electronic device requirements, then device size is reduced, but magnetic characteristics deteriorate
Solution Approach 1:
The patent changes the surface parameters of magnetic particles by forming indentations, which improves packing density and magnetic permeability. This allows miniaturized and thinned coil components to maintain magnetic characteristics comparable to or better than larger components, overcoming the typical deterioration of magnetic properties at smaller scales.
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 enhances magnetic permeability and packing factor of magnetic metal particles within the coil component, leading to improved magnetic characteristics and reduced losses, while maintaining the structural integrity and performance of the coil component.
Implementation Method 1
the body includes a plurality of magnetic metal particles, and a plurality of indentations are formed in surfaces of at least some of the plurality of magnetic metal particles
Data Source
AI summary
A coil component includes a body having a coil portion embedded therein; and external electrodes connected to the coil portion, wherein the body includes a plurality of magnetic metal particles, and a plurality of indentations are formed in surfaces of at least some of the plurality of magnetic metal particles, and the surfaces of the magnetic metal particles connecting the plurality of indentations to each other are spherical.