Coil Component with Non-Magnetic Layer for DC Superposition
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Solution Overview
Problem
Conventional metal inductors do not adequately meet the increasing demand for improved DC superposition characteristics, which are essential for modern electronic equipment with reduced size and increased current requirements.
Innovation Solution
A coil component is designed with a magnetic layer formed from a composite material of metal particles and resin, incorporating a non-magnetic layer between the magnetic layers and the coil conductor to enhance DC superposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a metal inductor is used to increase current handling capability, then current capacity is improved, but DC superposition characteristics deteriorate
Solution Approach 1:
The body is segmented into a magnetic layer and a non-magnetic layer. The magnetic layer (with metal particles) provides high permeability for inductance, while the non-magnetic layer (with resin material) provides electrical insulation to block eddy currents. This segmentation allows the inductor to handle high currents while maintaining good DC superposition characteristics by preventing harmful eddy current paths.
Solution Approach 2:
The body uses a composite structure combining magnetic material (metal particles) and non-magnetic material (resin material). The metal particles provide the necessary magnetic properties for inductance, while the resin material provides electrical insulation. This composite approach enables simultaneous achievement of high current capacity and excellent DC superposition characteristics.
2Volume of stationary object
If the body size is reduced to meet compact equipment requirements, then volume is improved, but inductance and strength deteriorate
Solution Approach 1:
The resin material in the non-magnetic layer provides mechanical strength and structural integrity, compensating for the reduced volume. The composite structure allows the inductor to maintain adequate bending strength and inductance even in a compact form factor, as the resin matrix binds the metal particles and provides structural support.
3Reliability
If a non-magnetic layer is added to improve DC superposition characteristics, then DC superposition characteristics are improved, but device complexity increases
Solution Approach 1:
The non-magnetic layer serves multiple functions simultaneously: it provides electrical insulation to block eddy currents, contributes to the mechanical strength of the body, and maintains structural integrity. By merging these functions into a single layer, the design achieves improved DC superposition characteristics without proportionally increasing complexity.
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 coil component achieves superior DC superposition characteristics by reducing magnetic flux density and minimizing eddy current losses, thereby increasing inductance and bending strength while maintaining a compact size.
Implementation Method 1
the non-magnetic layer is arranged to block between at least one of top and bottom surfaces of the body and the coil conductor
Data Source
AI summary
A coil component includes a body and a coil conductor embedded in the body. The body includes a magnetic layer and a non-magnetic layer. The magnetic layer is formed of a composite material including a metal particle and a resin material, and the non-magnetic layer is arranged to block between at least one of top and bottom surfaces of the body and the coil conductor.