Coil Component Structure With Non-Magnetic Layer for High-Current Inductance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coil components experience a decrease in inductance when high currents flow, leading to magnetic flux saturation, which is not effectively addressed in existing designs.
Innovation Solution
Incorporating a non-magnetic layer in the magnetic path around the coil and utilizing a support member without trimming to form the non-magnetic layer, which enhances current saturation properties and maintains inductance at high currents, while also reducing production lead time and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-magnetic layer is disposed in a magnetic path around the coil, then current saturation properties improve and inductance is maintained at high currents, but device complexity increases due to additional layer structure
Solution Approach 1:
The support member is designed to serve dual functions: providing mechanical support for the coil and acting as a non-magnetic layer in the magnetic path. By selecting non-magnetic materials (such as non-magnetic metals or non-metallic materials) for the support member, the structure automatically provides the magnetic path management function without requiring separate non-magnetic layers, thus improving current saturation properties while avoiding additional structural complexity
Solution Approach 2:
The support member is transformed from a single-function mechanical support structure into a multi-functional component that simultaneously provides mechanical support and magnetic path management. This universal design allows the same component to fulfill both structural and magnetic function requirements, resolving the contradiction between improved reliability and reduced device complexity
2Manufacturing precision
If the support member is trimmed to remove excess portions, then the coil component achieves precise dimensions, but production lead time increases due to additional trimming process
Solution Approach 1:
The support member is designed with pre-determined dimensions and shapes that directly match the final required dimensions of the coil component. By performing the dimensional design in advance during the support member fabrication stage, the need for subsequent trimming operations is eliminated, thereby achieving manufacturing precision without incurring additional time loss from post-processing steps
3Reliability
If additional processes are added to create the non-magnetic layer, then magnetic flux saturation properties improve, but productivity decreases due to increased manufacturing steps
Solution Approach 1:
The functions of mechanical support and magnetic path management are merged into a single integrated support member structure. By combining these functions into one component fabricated through standard processes, the patent eliminates the need for separate non-magnetic layer creation processes, thereby improving magnetic flux saturation properties while maintaining high productivity through process integration
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 improves current saturation properties, allowing the coil component to maintain inductance even at high currents and reduces production time by integrating the non-magnetic layer without additional processing steps.
Implementation Method 1
when a current (Isat) of a certain magnitude or more flows, magnetic flux density may be saturated and inductance may decrease
Implementation Method 2
magnetic flux density may be saturated and inductance may decrease
Data Source
AI summary
A coil component includes a body having first and second surfaces opposing each other, and third and fourth surfaces connected to the first and second surfaces and opposing each other, a support member disposed in the body, a coil disposed on at least one surface of the support member and including at least one turn around a core, a first non-magnetic layer extending from a side surface of the support member to the first to fourth surfaces of the body, and first and second external electrodes disposed on the body and connected to the coil.