Coil Component Coupling Adjustment via Magnetic Sheet
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Solution Overview
Problem
Existing coil components with a PCB substrate interposed between coils face challenges in achieving a high coupling coefficient without increasing the element body thickness, leading to larger sizes.
Innovation Solution
A coil component design featuring a metal powder-containing resin element body with overlapping coils, a magnetic sheet interposed between the coils, and an insulator to adjust the coupling coefficient while maintaining a thin profile, utilizing a magnetic sheet with higher permeability than the element body to control magnetic flux and reduce coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a PCB substrate is interposed between the pair of coils to adjust the coupling coefficient, then the coupling coefficient can be reduced, but the element body becomes thick and the size of the element is increased
Solution Approach 1:
The patent applies parameter changes by modifying the magnetic permeability of the magnetic sheet to adjust the coupling coefficient. By selecting magnetic sheets with different magnetic permeability values, the coupling coefficient can be precisely controlled without changing the physical dimensions of the element body, thus resolving the contradiction between coupling coefficient adjustment and thickness control.
Solution Approach 2:
The patent uses composite materials by introducing a magnetic sheet made of magnetic powder and resin between the coils. This magnetic sheet serves as an intermediate material that provides magnetic flux control capabilities, enabling coupling coefficient adjustment while maintaining a thin profile, thereby avoiding the need to increase element body thickness.
2Manufacturing precision
If the thickness of the PCB substrate is increased to reduce the coupling coefficient, then the coupling coefficient decreases, but the element body becomes thick
Solution Approach 1:
The patent changes the magnetic permeability parameter of the magnetic sheet to control the coupling coefficient. This approach allows precise adjustment of the coupling coefficient without increasing the element body volume, as the magnetic properties are modified rather than the physical dimensions.
Solution Approach 2:
The magnetic sheet acts as an intermediary between the two coils, providing a controlled magnetic path that adjusts the coupling coefficient. This intermediary material enables fine-tuning of magnetic coupling without requiring increased substrate thickness, thus maintaining compact element body volume.
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
Enables adjustment of the coupling coefficient while keeping the element body thickness minimal, effectively addressing the size and performance issues of traditional designs.
Implementation Method 1
by increasing the magnetic permeability of the magnetic sheet so that the magnetic flux generated in the coil easily passes through the magnetic sheet
Data Source
AI summary
In the coil component, the coupling coefficient can be adjusted by the magnetic sheet and the insulator interposed between the pair of coils. For example, by increasing the magnetic permeability of the magnetic sheet so that the magnetic flux generated in the coil easily passes through the magnetic sheet, the coupling coefficient decreases. In the coil component, the coupling coefficient can be adjusted while the thickness of the element body is suppressed.