Multilayer Coil Low-Permeability Layer Stress Dispersion
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Solution Overview
Problem
The multilayer coil component faces issues with crack generation due to shearing stress at the boundaries of different materials with varying shrinkage factors, affecting its direct-current superposition characteristic.
Innovation Solution
Incorporating a low-permeability layer with a lower permeability than the element body, which includes contact and separation portions, is disposed between internal conductors to block magnetic flux and disperse shearing stress, thereby preventing crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-magnetic layer is disposed between internal conductors to improve direct-current superposition characteristic, then magnetic saturation is suppressed, but internal stress and crack generation occur due to different shrinkage factors
Solution Approach 1:
A low-permeability layer is introduced as an intermediary between the internal conductors and the element body. This layer has permeability lower than the element body and includes a first portion contacting the internal conductors and a second portion separated from them. The low-permeability layer acts as a mediator that blocks magnetic flux while its boundaries crossing the first direction reduce stress concentration, preventing cracks despite the presence of shrinkage factor differences.
Solution Approach 2:
The low-permeability layer is strategically positioned with specific local properties: it has lower permeability than the element body and is disposed along the conductor portions between adjacent internal conductors. The layer's boundaries are designed to cross the first direction rather than run parallel to it, creating localized structural features that resist shearing stress while maintaining the magnetic flux blocking function where needed.
2Reliability
If materials with different shrinkage factors are used for magnetic portion, internal conductors, and non-magnetic layer, then direct-current superposition characteristic is improved, but shearing stress generates cracks at boundaries
Solution Approach 1:
The invention accepts that different shrinkage factors will generate internal stress, but converts this potentially harmful effect into a beneficial one by designing the low-permeability layer's boundaries to cross the first direction. This orientation transforms the stress concentration that would cause cracks into a stress-dispersing structure, where the boundaries themselves act as resistance against shearing stress while the low permeability still blocks magnetic flux effectively.
3Reliability
If low-permeability layer is disposed along conductor portions, then magnetic flux is blocked and direct-current superposition characteristic is improved, but structural integrity may be compromised due to boundary stress
Solution Approach 1:
The low-permeability layer is designed with an asymmetric configuration relative to the internal conductors. It includes a first portion contacting the conductors and a second portion separated from them, with boundaries that cross the first direction. This asymmetric design allows the layer to block magnetic flux along the conductor portions while the crossed boundaries provide structural stability by resisting shearing stress, preventing the symmetry-induced stress concentration that would occur with parallel boundaries.
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 solution effectively suppresses magnetic saturation and improves the direct-current superposition characteristic while reducing the likelihood of crack generation by dispersing shearing stress and optimizing the structural integrity of the coil component.
Implementation Method 1
The low-permeability layer has the permeability lower than the permeability of the element body and includes a first portion contacting the internal conductors. For this reason, magnetic flux generated around the individual internal conductors in the element body is blocked by the first portion of the low-permeability layer.
Implementation Method 2
the boundaries between the internal conductors and low-permeability layer and the element body are not formed along the first direction and include surfaces crossing the first direction. For this reason, the boundaries between the internal conductors and low-permeability layer and the element body function as resistances against a shearing stress along the first direction
Data Source
AI summary
A coil includes a plurality of internal conductors that are electrically connected to each other and are disposed in an element body having magnetism. The plurality of internal conductors includes conductor portions that are separated from each other in a first direction and overlap each other when viewed from the first direction. At least one low-permeability layer is disposed along the conductor portions between the internal conductors adjacent to each other in the first direction. Permeability of the low-permeability layer is lower than permeability of the element body. The low-permeability layer includes a first portion contacting the internal conductors and at least one second portion separated from the internal conductors in the first direction, between the internal conductors adjacent to each other. The element body includes first element body regions that are interposed between the second portion and the internal conductors.