Coil Component Magnetic Resin Layer Segmentation
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Solution Overview
Problem
The existing coil components face a reduction in inductance due to magnetic filler particles falling off from the magnetic resin layer during the polishing process, leading to a decrease in permeability.
Innovation Solution
A coil component design featuring a magnetic resin layer with a first layer in contact with the coil part and a second laminated layer with smaller maximum particle size magnetic fillers, where the second layer constitutes the principal surface, reducing the volume loss and maintaining permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a polishing process is performed on the magnetic resin layer to secure flatness, then the surface flatness is improved, but magnetic filler particles fall off from the magnetic resin layer causing volume reduction
Solution Approach 1:
The magnetic resin layer is divided into two distinct layers: a first magnetic resin layer containing larger magnetic filler particles that provides high permeability, and a second magnetic resin layer containing smaller magnetic filler particles that serves as a protective top layer. This segmentation allows the polishing process to be applied to the second layer without causing significant filler loss, while the first layer maintains the required magnetic properties.
Solution Approach 2:
Different regions of the magnetic resin layer are given different qualities: the first magnetic resin layer (bottom layer) contains larger magnetic filler particles for high permeability, while the second magnetic resin layer (top layer) contains smaller magnetic filler particles for protection during polishing. Each layer has optimized local properties suitable for its specific function in the overall structure.
2Manufacturing precision
If the magnetic resin layer is polished to maintain flatness, then the surface quality is improved, but the permeability of the coil component is reduced
Solution Approach 1:
The magnetic resin layer is segmented into two functional layers with different particle sizes. The first layer (larger particles) maintains high permeability and is protected from polishing damage by the second layer. The second layer (smaller particles) accepts the polishing process with minimal impact on overall permeability, thus resolving the contradiction between surface quality and magnetic performance.
Solution Approach 2:
The particle size parameter of magnetic filler is changed between layers: larger particles in the first layer for high permeability, and smaller particles in the second layer for polishing resistance. This parameter variation allows the structure to maintain permeability while withstanding the polishing process.
3Reliability
If larger magnetic filler particles are used in the magnetic resin layer, then the permeability is improved, but the magnetic filler is more prone to fall off during polishing
Solution Approach 1:
The magnetic resin layer is segmented into two layers with different particle sizes. The first layer contains larger magnetic filler particles that provide high permeability but are protected from polishing. The second layer contains smaller magnetic filler particles that are less prone to falling off during polishing, thus protecting the larger particles in the first layer.
Solution Approach 2:
Different particle sizes are assigned to different local regions: larger particles in the first layer for permeability, and smaller particles in the second layer for polishing stability. This local differentiation allows each layer to optimize its function without compromising the other.
Data Source
AI summary
Provided is a coil component that includes a coil part having a planar coil that includes a winding section and an insulating section covering the winding section, and a magnetic resin layer including a magnetic filler and configured to cover the coil part. The magnetic resin layer has a first magnetic resin layer that is in contact with the coil part and a second magnetic resin layer that is laminated on the first magnetic resin layer. The second magnetic resin layer constitutes a principal surface of the magnetic resin layer, and a maximum particle size of the magnetic filler contained in the second magnetic resin layer is larger than that of the magnetic filler contained in the first magnetic resin layer.