Coil Component Insulation Layout for Magnetic Volume Retention
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Solution Overview
Problem
As electronic devices become smaller, there is a need for coil components like inductors to be reduced in size while maintaining effective magnetic material volume.
Innovation Solution
A coil component design featuring a thin insulating layer with varying thicknesses on its surfaces and end surfaces, allowing for an increased effective volume of magnetic material within a reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the insulating layer thickness is reduced to minimize coil component size, then the overall component size is reduced, but the insulation reliability may deteriorate
Solution Approach 1:
The insulating layer is designed with non-uniform thickness, having a first thickness at the end surfaces and a second thickness at the lateral surfaces, where the first thickness is greater than the second thickness. This local quality variation allows the end surfaces to have enhanced insulation reliability while minimizing the overall component size through reduced thickness at lateral surfaces.
Solution Approach 2:
The insulating layer is segmented into different thickness regions: a first region at the end surfaces with greater thickness and a second region at the lateral surfaces with smaller thickness. This segmentation allows optimization of insulation reliability at critical areas (end surfaces) while reducing overall size through thinner insulation at less critical areas (lateral surfaces).
2Reliability
If the insulating layer thickness is increased to improve insulation reliability, then the insulation reliability is improved, but the effective volume of magnetic material is reduced
Solution Approach 1:
The insulating layer thickness is optimized locally: thicker at end surfaces where insulation reliability is critical, and thinner at lateral surfaces where space can be allocated to magnetic material. This resolves the contradiction by providing enhanced insulation only where needed rather than uniformly increasing thickness throughout.
Solution Approach 2:
The insulating layer is segmented into thickness zones that match the functional requirements of different surfaces. The first region (end surfaces) has greater thickness for reliability, while the second region (lateral surfaces) has smaller thickness to preserve magnetic material volume, achieving both goals simultaneously.
Data Source
AI summary
A coil component includes a body having one surface and the other surface, opposing each other, both lateral surfaces respectively connecting the one surface and the other surface and opposing each other, and both end surfaces respectively connecting the both lateral surfaces and opposing each other; a coil unit disposed in the body; a first external electrode and a second external electrode, respectively connected to the coil unit and disposed to be spaced apart from each other on the one surface of the body; and a first insulating layer covering the other surface of the body, the both lateral surfaces of the body, and the both end surfaces of the body.