Coil Component Magnetic Saturation Reduction
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Solution Overview
Problem
In coil components, magnetic saturation occurs due to concentrated magnetic flux at the end portion of the metal magnetic plate, leading to deterioration of direct current superimposition characteristics.
Innovation Solution
A coil component design featuring an insulation substrate with a penetration hole, a coil having a first and second flat coil pattern, and a magnetic body with a first magnetic portion and a second magnetic portion extending in the thickness direction, where the second magnetic portion has a higher Fe composition and protrudes beyond the coil's surface, reducing magnetic flux concentration and improving direct current superimposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a metal magnetic plate is placed close to the coil portion to increase inductance, then magnetic flux flows smoothly and inductance increases, but magnetic saturation occurs at the end portion due to concentrated magnetic flux, deteriorating direct current superimposition characteristics
Solution Approach 1:
The magnetic body is divided into two distinct portions: a first magnetic portion made of metal magnetic powder-containing resin that covers the coil, and a second magnetic portion made of ferrite that extends in the thickness direction in the inward region of the coil. This segmentation allows each portion to perform its specific function - the first portion provides high magnetic permeability for smooth flux flow, while the second portion with higher saturation magnetic flux density prevents magnetic saturation at critical locations.
Solution Approach 2:
Different magnetic materials are used in different locations within the magnetic body. The first magnetic portion uses metal magnetic powder-containing resin for high magnetic permeability, while the second magnetic portion uses ferrite for higher saturation magnetic flux density. This local differentiation of material properties optimizes both inductance enhancement and prevention of magnetic saturation at the end portion.
2Power
If a metal magnetic plate is used to enhance magnetic flux flow, then inductance increases, but the end portion experiences magnetic flux concentration leading to magnetic saturation
Solution Approach 1:
The second magnetic portion made of ferrite acts as an intermediary element with higher saturation magnetic flux density that is strategically positioned in the inward region of the coil. This intermediary portion intercepts and redistributes the magnetic flux, preventing excessive concentration at the end portion of the first magnetic portion, thereby avoiding magnetic saturation while maintaining efficient flux flow.
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 magnetic saturation, enhancing the direct current superimposition characteristics of the coil component by distributing magnetic flux more evenly.
Implementation Method 1
a first magnetic portion constituted of a metal magnetic powder-containing resin containing metal magnetic powders including Fe and covers the coil in at least a thickness direction of the insulation substrate, and a second magnetic portion extending in the thickness direction of the insulation substrate in an inward region of the coil and has a higher compositional proportion of Fe than the metal magnetic powder-containing resin constituting the first magnetic portion
Implementation Method 2
magnetic saturation occurs due to a magnetic flux concentrated at this place, and thus deterioration of direct current superimposition characteristics may be caused
Data Source
AI summary
An upper end portion and a lower end portion of a second magnetic portion of a coil component are further away from a coil than when a third part and a fifth part are not present. For this reason, a magnetic flux is unlikely to be concentrated in the upper end portion and the lower end portion of the second magnetic portion, so that magnetic saturation is unlikely to occur. Therefore, improvement of direct current superimposition characteristics is realized in the coil component.