Coil Component Magnetic Flux Shielding Layer
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Solution Overview
Problem
High-frequency coil components experience increased loss due to eddy currents as magnetic flux changes rapidly through the conductor, leading to inefficiencies and energy loss.
Innovation Solution
A coil component design featuring a base with magnetic material and insulating properties, a flat coil with specific lead conductor connections to external electrodes on one face of the base, minimizing the length and overlap of lead conductors to reduce eddy current and electrical resistance, thereby suppressing loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the coil component is used in high frequency bands, then the coil component can achieve lower inductances and thinner design, but the loss due to eddy current increases
Solution Approach 1:
The patent extracts the harmful magnetic flux path by introducing a magnetic flux shielding layer between the coil conductor and the lead conductor. This layer blocks the magnetic flux generated by the coil conductor from penetrating into the lead conductor, thereby eliminating the eddy current loss in the lead conductor while maintaining high-frequency operation capability
Solution Approach 2:
The patent introduces a magnetic flux shielding layer as an intermediary element between the coil conductor and the lead conductor. This intermediary layer serves as a magnetic flux barrier that prevents direct magnetic coupling between the two conductors, thereby reducing eddy current loss without affecting the electrical connection functionality
2Loss of energy
If the lead conductor is led out from the inner side to the outer side of the flat coil, then the connection is achieved, but the magnetic flux transmission through the lead conductor increases causing higher loss
Solution Approach 1:
The patent extracts the harmful magnetic flux from the lead conductor path by positioning the magnetic flux shielding layer to block the flux generated by the coil conductor. This allows the lead conductor to maintain its routing from inner side to outer side for ease of manufacture, while the harmful magnetic flux transmission is removed through the shielding layer
Solution Approach 2:
The magnetic flux shielding layer acts as an intermediary that decouples the magnetic interaction between the coil conductor and lead conductor. This allows the lead conductor to be routed conveniently from the inner side to outer side of the flat coil without directly transmitting the coil's magnetic flux, thereby reducing loss while maintaining manufacturing ease
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 effectively reduces eddy current-induced loss and maintains low electrical resistance, even at high frequencies, by optimizing lead conductor placement and configuration within the coil component.
Implementation Method 1
a magnetic flux shielding layer arranged between the coil conductor and the lead conductor in an overlapping area of the coil conductor and the lead conductor when viewed from above in a direction along a coil axis of the flat coil
Data Source
AI summary
In an exemplary embodiment, a coil component includes: a base part 10 containing a magnetic material; a flat coil 30 embedded in the base part 10, formed by a wound coil conductor 32 where an end part 34 and an end part 36 are located on the inner side and on the outer side of the windings, respectively; a lead conductor 50 and a lead conductor 52 connected to the end part 34 and the end part 36, respectively; an external electrode 60 and an external electrode 62 provided on the surface of the base part 10 and connected to the lead conductor 50 and the lead conductor 52, respectively. The lead conductor 50 is connected to the external electrode 60 in an area 42 on the inner side of the flat coil 30 as viewed from above in the axial direction of the flat coil 30.