Coil Component With Localized Pattern Width Enlargement
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Solution Overview
Problem
Existing coil components with alternately stacked interlayer insulating films and conductor layers have a constant coil pattern width, which limits the reduction of DC resistance.
Innovation Solution
A coil component design where the coil pattern width is locally enlarged by incorporating first and second terminal patterns with widened sections, allowing increased pattern width in specific sections, thereby reducing DC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil pattern width is kept constant throughout, then the manufacturing process is simple and structure is uniform, but the DC resistance cannot be reduced effectively
Solution Approach 1:
The patent applies local quality by varying the coil pattern width at different locations. Specifically, the coil pattern has a wider width in the radial direction at certain sections compared to other sections, allowing reduced DC resistance in high-current regions while maintaining uniform manufacturing processes overall. This localized variation optimizes electrical performance without complicating the overall manufacturing approach.
2Reliability
If the coil pattern width is locally enlarged, then the DC resistance is reduced, but the pattern width varies which may complicate manufacturing
Solution Approach 1:
The patent implements parameter changes by modifying the width dimension of the coil pattern at specific locations. The coil pattern width is changed from a constant value to a variable value that is larger in the radial direction at selected sections. This parameter variation reduces DC resistance while the overall fabrication process remains compatible with standard manufacturing techniques, as the width variation is incorporated into the pattern design rather than requiring separate manufacturing steps.
Data Source
AI summary
Disclosed herein is a coil component that includes a conductor layer including a coil pattern and a terminal pattern provided independently of the coil pattern and exposed from the magnetic element body. The terminal pattern includes a linear part having a substantially constant pattern width in a direction perpendicular to the side surface of the magnetic element body, a widened part positioned at one end side in a second direction. The outermost turn of the coil pattern includes a first section provided along the linear part, a second section provided along the widened part, and a fourth section provided along the magnetic element body and positioned on a side opposite to the first section with respect to the second section. The pattern width of the coil pattern is larger in the second sections than in the first and fourth sections.