Multilayer Coil Protrusions Reduce Stray Capacitance
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Solution Overview
Problem
Existing multilayer coil components face challenges in noise suppression in high frequency bands due to resonance issues and lack of effective inspection systems for defective components, leading to degraded impedance characteristics and improper noise removal.
Innovation Solution
A multilayer coil component with a vertically-wound structure featuring magnetic layers and inner electrode layers with protrusions, which reduce stray capacitance and increase impedance, combined with an inspection system that checks for protrusion exposure to identify defective products, ensuring efficient noise removal in high frequency bands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a vertically-wound structure is used to achieve low DC resistance, then DC resistance is reduced, but stray capacitance increases and impedance decreases in high frequency bands
Solution Approach 1:
The patent applies local quality by creating protrusions at specific locations (outer edges of inner electrode layers) to locally reduce stray capacitance. This allows the vertically-wound structure to maintain low DC resistance while the protrusions locally mitigate the capacitance issue that degrades high-frequency impedance characteristics.
Solution Approach 2:
The patent changes the geometric parameters of the inner electrode layers by adding protrusions that extend beyond the magnetic layers. This parameter change reduces the stray capacitance between the coil conductor and outer electrodes, thereby improving impedance characteristics in high frequency bands while maintaining the vertically-wound structure's low DC resistance advantage.
2Reliability
If protrusions are added to inner electrode layers to reduce stray capacitance, then impedance in high frequency band is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the protrusions during the electrode layer formation process itself, before final assembly. The inner electrode layers are designed with protrusions that extend beyond the magnetic layers, allowing the stray capacitance reduction to be built into the structure during manufacturing rather than requiring additional post-processing steps.
3Productivity
If conventional multi-piece production technique is used, then manufacturing efficiency is maintained, but defective components with degraded impedance characteristics cannot be identified
Solution Approach 1:
The patent uses the visual appearance change (protrusion exposure) as an indicator of defective components. By designing the inner electrode layers with protrusions that should be covered by magnetic layers, defective components where protrusions are exposed can be easily identified through visual inspection or automated optical inspection systems, enabling quality control without affecting manufacturing efficiency.
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 minimizes stray capacitance, maintains high impedance characteristics, and quickly identifies defective components at a low cost, ensuring reliable noise suppression in high frequency bands.
Implementation Method 1
The inner electrode layers have protrusions protruding from both outer edges extending in a length direction of the element body... This reduces stray capacitance between the coil conductor and the outer electrodes
Implementation Method 2
inner electrode layers laminated with the magnetic layers alternately on one another... The inner electrode layers are electrically connected to each other to form a helical coil conductor buried in the element body
Data Source
AI summary
A multilayer coil component includes magnetic layers and inner electrode layers that are alternately laminated on one another. The inner electrode layers are electrically connected to each other to constitute a helical coil conductor. The coil conductor is buried in an element body composed of the magnetic layers. Outer electrodes having folded portions are disposed on both end portions of the element body. The inner electrode layers of the coil conductor have protrusions protruding from both outer edges extending in a length direction of the element body.