Coil Component With Segmented Magnetic Base For High Permeability
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Solution Overview
Problem
The challenge is to enhance the magnetic permeability of coil components made from composite materials containing metal particles and resin, while maintaining structural integrity and avoiding deformation during compression molding, which typically limits the filling factor of metal particles.
Innovation Solution
Incorporating a magnetic base with a protrusion portion and an outer coating, where the protrusion is inserted into the coil conductor's core, allowing for a higher filling factor of metal particles and increased magnetic permeability without compromising the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If compression molding pressure is increased to maximize metal particle filling factor, then magnetic permeability is improved, but coil deformation occurs
Solution Approach 1:
The magnetic portion is divided into two distinct parts: a magnetic base with high filling factor and an outer coating with lower filling factor. This segmentation allows the core region to have maximum metal particle density for high magnetic permeability, while the outer coating provides structural support and protects the coil from deformation during compression molding.
Solution Approach 2:
Different regions of the magnetic portion are given different metal particle filling factors. The magnetic base (core portion) has a high filling factor to maximize magnetic permeability, while the outer coating has a lower filling factor to maintain structural integrity and prevent coil deformation. This local differentiation of material properties resolves the contradiction between maximizing magnetic performance and maintaining structural stability.
2Quantity of substance
If metal particle filling factor is maximized to obtain high magnetic permeability, then inductance is improved, but structural integrity is compromised
Solution Approach 1:
The magnetic portion is segmented into a magnetic base and an outer coating, each serving different functional requirements. The magnetic base contains the high filling factor for magnetic performance, while the outer coating provides the structural integrity needed for reliability.
Solution Approach 2:
The magnetic portion uses a composite structure combining two different composite materials: one with high metal particle content for magnetic properties and another with lower metal particle content for structural properties. This composite approach allows simultaneous achievement of high magnetic permeability and structural integrity.
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 achieves higher inductance and magnetic permeability by maximizing the filling factor of metal particles in the magnetic base, while maintaining the coil's integrity and reliability.
Implementation Method 1
the magnetic permeability of the magnetic portion, especially of the core portion, has to be enhanced. In order to enhance the magnetic permeability of the magnetic portion of the coil component made of a composite material including metal particles and a resin material, it is preferable that the filling factor of the metal particles in the magnetic portion be maximized
Implementation Method 2
The magnetic portion includes an outer coating and a magnetic base having a protrusion portion, and the protrusion portions is inserted into a core portion of the coil conductor and the outer coating covers the coil conductor
Data Source
AI summary
A coil component includes a magnetic portion that includes metal particles and a resin material, a coil conductor embedded in the magnetic portion and having a core portion, and outer electrodes electrically connected to the coil conductor. The magnetic portion includes an outer coating and a magnetic base having a protrusion portion. The protrusion portion is inserted into the core portion. The filling factor of the metal particles in the magnetic base is higher than the filling factor of the metal particles in the outer coating.