Coil Component Using Oriented Metal Powder for DC-Bias
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Solution Overview
Problem
Inductors with ferrite as magnetic material have low saturation magnetization, leading to significant changes in inductance with current application, limiting their performance.
Innovation Solution
A coil electronic component using metal powder particles with shape anisotropy or a magnetic metal plate, oriented to align with the magnetic flux direction, enhancing inductance and Q factor, and DC-bias characteristics by optimizing the arrangement and structure of the coil unit and external electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ferrite is used as magnetic material, then manufacturing is easier and cost is lower, but saturation magnetization is low causing significant inductance change with current application
Solution Approach 1:
The patent changes the material parameter from ferrite to metal powder particles with shape anisotropy, which have higher saturation magnetization values. This material substitution resolves the contradiction by maintaining ease of manufacture through powder metallurgy processes while significantly improving DC-bias properties and reducing inductance change under current application.
Solution Approach 2:
The patent employs composite structures by combining metal powder particles with shape anisotropy in specific orientations within the magnetic core. This composite approach allows achieving high saturation magnetization while maintaining manufacturability through controlled particle arrangement and binding techniques.
2Reliability
If metal powder particles with shape anisotropy are used and oriented with magnetic flux direction, then inductance and Q factor are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by orienting metal powder particles with shape anisotropy specifically along the magnetic flux direction in critical regions of the core. This selective orientation enhances Q factor and inductance where needed while simplifying other areas, resolving the contradiction between performance enhancement and manufacturing complexity.
Solution Approach 2:
The patent employs preliminary action by pre-orienting metal powder particles with shape anisotropy along the magnetic flux direction during the manufacturing process, before final assembly. This preliminary orientation simplifies subsequent manufacturing steps while achieving the desired enhancement in Q factor and inductance.
3Loss of energy
If metal powder particles are oriented parallel to magnetic flux direction, then magnetic permeability increases and core loss decreases, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the manufacturing approach by using metal powder particles with inherent shape anisotropy that naturally align with magnetic flux directions during processing. This parameter change in material selection and orientation method reduces core loss while maintaining reasonable manufacturing precision requirements through self-alignment properties.
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 achieves high inductance, excellent Q factor, and improved DC-bias properties by aligning metal powder particles or magnetic metal plates with the magnetic flux direction, reducing core loss and enhancing magnetic permeability.
Implementation Method 1
a metal powder particle having shape anisotropy or a magnetic metal plate formed around a coil unit, in which the metal powder particle having shape anisotropy or the magnetic metal plate are arranged to be oriented in a direction of flow of magnetic flux generated by the coil unit
Implementation Method 2
enhancing inductance and Q factor, and DC-bias characteristics by optimizing the arrangement and structure of the coil unit and external electrodes
Implementation Method 3
magnetic flux generated by the coil unit
Implementation Method 4
reducing core loss and enhancing magnetic permeability
Data Source
AI summary
A coil electronic component includes a body including metal powder particles having shape anisotropy and a coil unit disposed in the body and having an axis perpendicular with respect to a thickness direction of the body. The metal powder particles having shape anisotropy are arranged such that a plane-shaped surface thereof is parallel to a direction of flow of magnetic flux.