Carbon-Particle Insulating Layer for Miniaturized Coil Components
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Solution Overview
Problem
Coil components with metal magnetic materials face low voltage resistance, leading to electrical breakdown, and existing insulation coatings, while effective, hinder miniaturization and increase static charging due to their thickness and properties.
Innovation Solution
A coil component design featuring a base body with a metal magnetic material, a conductor, and an insulating layer containing carbon particles and inorganic fillers, with the insulating layer covering the entire surface and having a thickness of less than 10 μm to enhance voltage resistance and reduce static charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation coat is provided to secure voltage resistance, then electrical breakdown is prevented, but the component size increases and miniaturization is hindered
Solution Approach 1:
The patent changes the material composition parameters of the insulating layer by incorporating carbon particles (0.01-5 wt%) and specific inorganic fillers (silica, alumina, titania) in controlled amounts. This material parameter modification enables the insulating layer to achieve adequate voltage resistance with reduced thickness, thus preventing electrical breakdown while minimizing size increase
Solution Approach 2:
The patent creates a composite insulating layer by combining resin base material with carbon particles and inorganic fillers. This composite structure provides both electrical insulation properties and mechanical stability, achieving effective voltage resistance with a thinner layer that does not significantly increase component size
2Reliability
If a thick insulation coat is provided to ensure complete coverage and voltage resistance, then electrical breakdown is prevented, but the component cannot be miniaturized
Solution Approach 1:
The patent optimizes the thickness parameter of the insulating layer to 1-10 μm by modifying the material composition. The inclusion of carbon particles and inorganic fillers enhances the electrical insulation performance per unit thickness, allowing the layer to be much thinner than conventional insulation coats while still preventing electrical breakdown effectively
Solution Approach 2:
The patent uses a thin insulating layer that copies or replicates the essential insulation function of much thicker conventional coatings. By utilizing carbon particles and inorganic fillers, the thin layer achieves comparable or superior insulation effectiveness without the size penalty of thick coatings
3Reliability
If conventional insulation materials are used to secure insulation, then voltage resistance is improved, but static charging increases during manufacturing and handling
Solution Approach 1:
The patent changes the electrical properties parameter of the insulating layer by incorporating carbon particles, which are conductive. This modification creates a material that can dissipate static electricity while maintaining adequate insulation properties, thus reducing static charging during manufacturing and handling compared to conventional purely insulating materials
Solution Approach 2:
The carbon particles act as an intermediary substance within the insulating layer, providing a pathway for static charge dissipation. These particles mediate between the need for electrical insulation and the need to prevent static charging, enabling the layer to perform both functions simultaneously
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 secures insulating properties while minimizing size constraints and static charging, ensuring reliable operation and safe handling of the coil components.
Implementation Method 1
an insulating layer that is provided on a surface of the magnetic body portion in the base body and that is a resin containing carbon particles
Implementation Method 2
the insulation coat also makes the coil component more easily charged due to friction and other factors. Therefore, measures against static electricity are also important
Implementation Method 3
the insulating layer contains an insulating inorganic filler
Implementation Method 4
the core loss of the dust core may change in a high temperature environment. In other words, a change in core loss can lead to the degradation of insulation during exposure to a high temperature environment
Implementation Method 5
an insulating layer that is provided on a surface of the magnetic body portion in the base body and that is a resin containing carbon particles
Data Source
AI summary
Disclosed herein is a coil component including a base body having a magnetic body portion containing a metal magnetic material, a conductor provided inside the base body, an insulating layer that is provided on a surface of the magnetic body portion in the base body and that is a resin containing carbon particles, and an external electrode that extends along the surface of the base body and that is connected to the conductor.