Low-Profile Coil Component With Graded Cover Thickness
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Solution Overview
Problem
Low-profile coil components face thickness asymmetry and magnetic flux concentration issues, leading to deteriorated characteristics such as series inductance and DC-BIAS, due to thinning cover portions.
Innovation Solution
A coil component design with varying thickness in the cover portion, where the innermost turn has a thicker cover portion than the outermost turn, and the wound coil has equal cross-sectional areas but different widths for turns, to manage magnetic flux distribution and prevent necking phenomena.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the cover portion is thinned to achieve low-profile, then the overall thickness is reduced, but magnetic flux concentration and necking phenomenon occur leading to deteriorated component characteristics
Solution Approach 1:
The cover portion is designed with non-uniform thickness, being thicker at the central portion and thinner at the outer portion. This local variation in thickness allows the central region to maintain sufficient magnetic path length and prevent flux concentration, while the overall component achieves reduced profile thickness.
Solution Approach 2:
The cover portion employs an asymmetric thickness distribution rather than uniform thickness. The thickness varies from the central portion to the outer portion, creating an asymmetric structure that optimizes magnetic flux distribution while achieving low-profile dimensions.
2Length of moving object
If the cover portion thickness is reduced, then the low-profile requirement is met, but thickness asymmetry between magnetic mold and cover portion worsens
Solution Approach 1:
The cover portion thickness is locally optimized with a gradient distribution, being thicker at the center and thinner at the periphery. This local quality variation balances the thickness asymmetry between the magnetic mold and cover portion, ensuring structural stability while achieving low-profile requirements.
3Length of moving object
If the cover portion becomes thinner, then the overall component thickness is reduced, but magnetic flux necking occurs at the cover portion
Solution Approach 1:
The cover portion is designed with locally varying thickness, being thicker at the central portion where magnetic flux density is highest. This local thickening prevents magnetic flux necking and concentration, while the overall component maintains reduced thickness through thinner outer regions.
Solution Approach 2:
The cover portion thickness is preliminarily designed to be greater at the central portion to preemptively counteract the magnetic flux concentration and necking effect before it occurs. This preliminary anti-action prevents the harmful magnetic flux necking phenomenon while achieving low-profile dimensions.
Data Source
AI summary
A coil component includes a molded portion having one surface and another surface opposing each other, and a wound coil disposed on the one surface of the molded portion and including an innermost turn, at least one intermediate turn, and an outermost turn disposed outwardly of a central portion of the one surface of the molded portion. A cover portion is disposed to face the one surface of the molded portion and to cover the wound coil, and first and second external electrodes are connected to the wound coil and arranged to be spaced apart from each other on the other surface of the molded portion. A thickness of one region of the cover portion disposed on the innermost turn is thicker than a thickness of another region of the cover portion disposed on the outermost turn.