Laminated Coil Component Thickness Reduction via Segmented Insulation
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Solution Overview
Problem
The challenge is to reduce the thickness of laminated coil components while maintaining sufficient dielectric strength, as reducing the insulating intermediate part between conductor layers can lead to a decrease in dielectric strength.
Innovation Solution
A coil component design featuring a magnetic body with a rectangular solid shape, multiple winding parts, and an insulating intermediate part with a non-magnetic material, where the insulating intermediate part is positioned between the conductor layers and has a thickness equal to or less than the product of the inter-conductor distance and the number of turns minus one, ensuring sufficient dielectric strength and allowing for thickness reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the insulating intermediate part between conductor layers is reduced in thickness, then the overall component thickness is reduced, but the dielectric strength decreases
Solution Approach 1:
The insulating intermediate part is segmented into multiple regions with different dielectric constants. The first insulating region has a higher dielectric constant than the second insulating region, allowing the overall thickness to be reduced while maintaining sufficient dielectric strength through the high-dielectric region.
Solution Approach 2:
Different regions of the insulating intermediate part are assigned different dielectric properties. The first insulating region positioned near the conductor patterns has higher dielectric constant to provide strong local insulation where electric field intensity is highest, while the second region can be thinner with lower dielectric constant.
2Length of moving object
If the insulating intermediate part is reduced to enable thickness reduction, then the component becomes thinner, but the spacing between conductor layers is insufficient
Solution Approach 1:
The dielectric constant parameter is changed across different regions of the insulating intermediate part. By using materials with different dielectric constants in different regions, the effective insulation distance is increased without proportionally increasing the physical thickness, thus maintaining adequate spacing functionality in a thinner profile.
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
This design enables thickness reduction while maintaining sufficient dielectric strength, reducing the overall length of the coil and lowering direct-current resistance, while also improving inductance due to the magnetic permeability of the magnetic body.
Implementation Method 1
improving inductance due to the magnetic permeability of the magnetic body
Implementation Method 2
ensuring sufficient dielectric strength at the same time
Data Source
AI summary
A coil component has a magnetic body of rectangular solid shape, a coil with N turns (N is a positive number of 2 or greater) provided inside the magnetic body, an insulating intermediate part, and external electrodes. The coil has a first conductor layer, a second conductor layer, and an inter-layer connection part. The first conductor layer has a first multiple winding part which is wound around one axis with a first spacing. The second conductor layer has a second multiple winding part which is wound around the one axis with the first spacing and faces the first conductor layer. The insulating intermediate part is provided inside the magnetic body and forms, between the first conductor layer and second conductor layer, a second spacing corresponding to a thickness equal to or less than the product of the first spacing and (N−1).