Magnetic Particle Coil Component for High Permeability Packing
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Solution Overview
Problem
Existing coil components face challenges in achieving high effective magnetic permeability and saturation magnetic flux density due to low filling factor of metal magnetic particles, particularly when the aspect ratio of large particles increases, leading to a drop in saturation magnetic flux density.
Innovation Solution
A coil component design incorporating a mixture of metal magnetic particles with different aspect ratios, where smaller particles have a higher aspect ratio than larger particles, oriented in a specific direction to maintain filling factor while enhancing effective magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the aspect ratio of large metal magnetic particles is increased to improve effective magnetic permeability, then effective magnetic permeability is improved, but filling factor drops significantly
Solution Approach 1:
The invention changes the particle size distribution parameters by introducing a bimodal mixture where small particles (0.3-1.0 μm) have aspect ratio ≥2.0 and large particles (1.0-3.0 μm) have aspect ratio 1.0-2.0. This parameter optimization allows small particles to fill interstices between large particles, maintaining high filling factor (≥60%) while achieving high effective magnetic permeability (≥100).
Solution Approach 2:
The invention creates a composite particle system combining two distinct metal magnetic particle populations with different size ranges and aspect ratios. The small particles with higher aspect ratio complement the large particles with lower aspect ratio, forming a composite structure that simultaneously achieves high filling factor and high effective magnetic permeability, resolving the trade-off between these two 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 design achieves high effective magnetic permeability and saturation magnetic flux density by optimizing the aspect ratio of smaller particles to prevent a drop in filling factor, resulting in improved performance for large-current circuits.
Implementation Method 1
the small particles and the large particles are oriented in a reference direction
Implementation Method 2
the metal magnetic particles are flattened to have an aspect ratio of 2 or more
Implementation Method 3
a base body made of a magnetic material, a coil conductor provided in the base body
Data Source
AI summary
An embodiment provides a coil component including a base body, and a coil conductor provided in the base body. At least partial region of the base body contains (i) a plurality of first metal magnetic particles having a first aspect ratio greater than one and having a first average particle size and (ii) a plurality of second metal magnetic particles having a second aspect ratio greater than the first aspect ratio, having a second average particle size less than the first average particle size. The first and second metal magnetic particles are oriented in a reference direction in the base body.