Coil Component Multi-Size Magnetic Particle Distribution
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Solution Overview
Problem
Existing coil components, such as inductors, face challenges in achieving optimal inductance and permittivity due to limitations in magnetic particle distribution and density, which affect their performance in electronic circuits.
Innovation Solution
A coil component is manufactured using a body with a specific grain size distribution of magnetic particles, including first, second, and third magnetic particles with differing diameters, ranging from 8 μm to 30 μm, 2.5 μm to 5.0 μm, and less than 1.5 μm, respectively, to improve density and permittivity, thereby enhancing inductance and inductor saturation values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single size of magnetic particles is used in the body, then the manufacturing process is simple, but the density and permittivity of the coil component are insufficient
Solution Approach 1:
The patent applies parameter changes by varying the grain size of magnetic particles across three distinct peaks (first peak: fine particles, second peak: medium particles, third peak: coarse particles). This multi-size distribution optimizes both density and permittivity while maintaining manufacturability through controlled particle selection and mixing ratios.
Solution Approach 2:
The patent uses composite materials by combining magnetic particles of three different grain sizes within the resin matrix. This composite structure allows fine particles to fill gaps between larger particles, increasing overall density and improving permittivity without significantly complicating the manufacturing process.
2Quantity of substance
If magnetic particles with larger grain size are used, then the permittivity increases, but the density and inductor saturation performance deteriorate
Solution Approach 1:
The patent applies local quality by assigning different grain sizes to different regions of the magnetic particle distribution. Coarse particles (third peak) provide high permittivity in specific areas, while fine particles (first peak) maintain density and saturation performance in other regions, creating a heterogeneous but optimized overall structure.
Solution Approach 2:
The patent resolves this contradiction through parameter changes by establishing specific grain size ratios where the third peak particles are 4-15 times larger than second peak particles, and second peak particles are 2-7 times larger than first peak particles. This controlled parameter variation optimizes both permittivity and inductor saturation performance simultaneously.
3Quantity of substance
If magnetic particles with smaller grain size are used, then the density increases, but the permittivity and inductance performance deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the magnetic particle population into three distinct size segments (peaks). Fine particles (first peak) provide high density, while coarse particles (third peak) contribute to high permittivity and inductance. This segmentation allows each particle size to fulfill its specific functional role without compromising overall performance.
Data Source
AI summary
A coil component includes a body having a coil part disposed therein and an external electrode connected to the coil part. The body includes magnetic particles, and the magnetic particles include first magnetic particles, second magnetic particles, and third magnetic particles. A diameter of each of the first, second, and third magnetic particles is different from each other.