Coil Component with Interlayer Spiral Slits for AC Resistance Reduction
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Solution Overview
Problem
In coil components with spiral-shaped planar conductors formed on both sides of an insulating substrate, there is a significant difference in electrical lengths between inner and outer peripheral conductor parts due to radial separation by spiral-shaped slits, leading to increased AC resistance.
Innovation Solution
The coil component design includes two spiral coil parts on opposite surfaces of an insulating substrate, where the innermost turns are radially separated into multiple conductor parts by spiral-shaped slits, and these parts are interconnected to equalize the electrical lengths, allowing for reduced non-uniformity in current density distribution and minimized AC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If radial positions of conductive wires are interchanged to equalize electrical lengths, then AC resistance is reduced, but in a planar conductor configuration only two layers are available, preventing the layout from being realized
Solution Approach 1:
The patent resolves the layout complexity issue by transitioning from a two-dimensional planar arrangement to a three-dimensional structure utilizing both front and back surfaces of the substrate. This allows conductor parts to be interconnected across layers, achieving radial position interchange and electrical length equalization without the crossing problems that would occur in a single-plane configuration.
Data Source
AI summary
Disclosed herein is a coil component that includes an insulating substrate, a first coil part formed on the first surface of the insulating substrate, and a second coil part formed on the second surface of the insulating substrate. At least an innermost turn of the first coil part is radially separated by spiral-shaped slits into three or more conductor parts. At least an innermost turn of the second coil part is radially separated by spiral-shaped slits into three or more conductor parts. Inner peripheral ends of respective innermost to outermost conductor parts of the three or more conductor parts of the first coil part are connected to inner peripheral ends of the respective outermost to innermost conductor parts of the three or more conductor parts of the second coil part.