Coil Component Segmented Magnetic Body Prevents Short Circuit
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Solution Overview
Problem
The existing coil components face a risk of short-circuiting due to a higher proportion of metal magnetic powder in the first magnetic body, leading to a lower withstand voltage, which can cause a short circuit between the coil and external electrodes.
Innovation Solution
A coil component design featuring a first magnetic portion with a higher metal magnetic powder content on the outer surface and a second magnetic portion with a higher Fe composition, but lower withstand voltage, positioned internally to prevent direct contact with external electrodes, ensuring the coil and external terminal electrodes do not short-circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a higher proportion of metal magnetic powder is used in the first magnetic body to improve magnetic flux density, then the magnetic flux density is improved, but the withstand voltage decreases leading to short circuit risk
Solution Approach 1:
The magnetic body is divided into two distinct magnetic portions: a first magnetic portion with higher metal magnetic powder content for high magnetic flux density near the coil, and a second magnetic portion with lower metal magnetic powder content for high withstand voltage on the outer surface. This segmentation allows each portion to optimize its material composition for its specific functional requirement without compromise.
Solution Approach 2:
Different regions of the magnetic body are assigned different material compositions tailored to local requirements. The first magnetic portion (inner region) uses high metal magnetic powder content (70-90 wt%) to maximize magnetic flux density where it is most needed near the coil. The second magnetic portion (outer region) uses lower metal magnetic powder content (30-70 wt%) to provide high withstand voltage and prevent short circuits with external electrodes.
2Reliability
If a second magnetic portion with higher Fe composition is positioned internally to prevent short-circuiting, then the withstand voltage is improved, but the magnetic flux flow may be hindered
Solution Approach 1:
The magnetic body is segmented into an inner first magnetic portion optimized for magnetic flux generation and an outer second magnetic portion optimized for electrical insulation. The first magnetic portion contains 70-90 wt% metal magnetic powder to ensure strong magnetic flux flow, while the second magnetic portion contains 30-70 wt% metal magnetic powder to provide adequate withstand voltage, preventing short circuits with external electrodes.
Solution Approach 2:
The magnetic body exhibits spatially varying material properties: the inner region (first magnetic portion) has high metal magnetic powder content for optimal magnetic flux density and flow characteristics, while the outer region (second magnetic portion) has reduced metal magnetic powder content to enhance electrical insulation properties and withstand voltage capability.
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 design effectively prevents short-circuiting by maintaining a higher withstand voltage for the external terminal electrodes and ensuring smooth magnetic flux flow, while the second magnetic portion's high saturation magnetic flux density enhances magnetic flux distribution within the coil.
Implementation Method 1
a second magnetic portion surrounded by the first magnetic portion, the second magnetic portion covering at least a part of the coil, and having a higher compositional proportion of Fe than the metal magnetic powder-containing resin constituting the first magnetic portion
Implementation Method 2
the first magnetic portion having a comparatively low withstand voltage... the second magnetic portion having a relatively lower withstand voltage than the first magnetic portion... the external terminal electrodes provided on the outer surface of the magnetic body and the second magnetic portion do not come into contact with each other
Data Source
AI summary
In a coil component, a second magnetic portion disposed in the vicinity of a coil is designed to have a higher proportion of Fe than a metal magnetic powder-containing resin constituting a first magnetic portion. Therefore, a magnetic flux of the coil flows smoothly. Although the second magnetic portion has a relatively lower withstand voltage than the first magnetic portion, since the second magnetic portion is surrounded by the first magnetic portion, it is not exposed on an outer surface of a magnetic body. For this reason, a situation in which the coil and external terminal electrodes are short-circuited with the second magnetic portion therebetween is effectively curbed, and short-circuiting between the coil and the external terminal electrodes can be curbed.