Coil Component With Density-Graded Magnetic Top Plate
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Solution Overview
Problem
The challenge is to create a coil component with a drum core that achieves a lower height while minimizing magnetic flux leakage and ensuring the structural integrity of the magnetic top plate, which is often compromised by reducing its thickness, and addressing the differing characteristics between the front and back sides of a magnetic top plate made of magnetic-powder containing resin.
Innovation Solution
A coil component design featuring a drum core with wound wires and terminal electrodes, where the magnetic top plate is made of magnetic-powder containing resin with varying binder resin densities on its surfaces, enhancing insulation on the upper surface and magnetic properties on the lower surface, and using soft magnetic metal powder for improved magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of the magnetic top plate is reduced to achieve lower height, then the height of the coil component is reduced, but the strength of the magnetic top plate becomes insufficient and it may be broken
Solution Approach 1:
The patent changes the material composition parameters of the magnetic top plate by incorporating magnetic powder into resin, allowing the plate to maintain sufficient strength even when thinned. This material parameter modification enables the magnetic top plate to achieve both reduced thickness for lower component height and maintained structural integrity
Solution Approach 2:
The patent uses composite materials by combining magnetic powder with resin to create the magnetic top plate. This composite structure provides both the necessary magnetic properties and mechanical strength, allowing the plate to be thinner without compromising strength, thus resolving the contradiction between reduced height and maintained strength
2Length of moving object
If the magnetic top plate is thinned to reduce height, then the height of the coil component is reduced, but leakage of magnetic flux increases
Solution Approach 1:
The patent modifies the material composition of the magnetic top plate by incorporating magnetic powder into the resin matrix. This parameter change enhances the magnetic properties of the thinned plate, allowing it to effectively contain magnetic flux even at reduced thickness, thus preventing magnetic flux leakage while achieving lower component height
Solution Approach 2:
By using composite materials consisting of magnetic powder and resin, the patent creates a magnetic top plate that maintains effective magnetic shielding properties even when thinned. The magnetic powder particles distributed in the resin provide the necessary magnetic permeability to contain flux, resolving the contradiction between reduced height and magnetic flux containment
3Strength
If magnetic-powder containing resin is used as the material of the magnetic top plate to maintain strength when thinned, then strength is maintained, but distribution of binder resin and magnetic powder is not uniform
Solution Approach 1:
The patent applies local quality by creating non-uniform distribution of magnetic powder and binder resin within the magnetic top plate. Specifically, the binder resin density is made higher in the surface layer part on the upper surface side than in the surface layer part on the lower surface side, optimizing different regions for different functions (insulation on upper surface, magnetic properties on lower surface)
4Reliability
If the density of binder resin is increased in the surface layer part on the upper surface side to improve insulation, then insulation properties are improved, but magnetic properties may be affected
Solution Approach 1:
The patent resolves this contradiction by applying local quality - making the binder resin density higher specifically in the upper surface region for insulation, while maintaining lower binder resin density (higher magnetic powder density) in the lower surface region for magnetic properties. This spatial variation in composition allows both insulation and magnetic functionality to be optimized simultaneously in different regions of the same component
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
This design prevents short circuit failures by increasing insulation on the upper surface and optimizing magnetic properties, while maintaining structural integrity and reducing magnetic flux leakage, thus achieving high reliability and magnetic performance.
Implementation Method 1
a magnetic top plate made of magnetic-powder containing resin in which magnetic powder is mixed in binder resin, being fixed to the first and second flange portions
Implementation Method 2
magnetic-powder containing resin having flexibility instead of using ferrite as a material of the magnetic top plate. The magnetic-powder containing resin can maintain certain strength even if it is thinned
Implementation Method 3
the density of the binder resin is higher in a surface layer part on the side of the upper surface than in a surface layer part on the side of the lower surface. Because the density of the binder resin is high in the surface layer part on the side of the upper surface of the magnetic top plate, insulation properties on the upper surface of the magnetic top plate are increased
Implementation Method 4
Because the density of the binder resin is low in the surface layer part on the side of the lower surface of the magnetic top plate, a magnetic path via the magnetic top plate becomes short, thereby enabling to obtain high magnetic properties
Data Source
AI summary
Disclosed herein is a coil component that includes a drum core having a winding core and first and second flange portions provided at opposite ends of the winding core; a wire wound around the winding core; terminal electrodes provided in the first and second flange portions, the terminal electrodes being connected to ends of the wire; and a magnetic top plate made of magnetic-powder containing resin in which magnetic powder is mixed in binder resin, the magnetic top plate being fixed to the first and second flange portions. The magnetic top plate has a lower surface facing the first and second flange portions and an upper surface located opposite to the lower surface. The density of the binder resin is higher in a surface layer part on a side of the upper surface than in a surface layer part on a side of the lower surface.