Coil Component With Segmented Magnetic Layers

Solution Overview

Problem

Conventional metal inductors fail to meet the increasing demand for improved DC superposition characteristics and are affected by leakage magnetic flux due to the densification of electronic components.

Innovation Solution

A coil component with a body comprising a magnetic layer made of a composite material including metal particles and resin, combined with a non-magnetic layer that does not extend through the winding portion or the entire body, enhancing DC superposition characteristics and reducing leakage magnetic flux.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional metal inductor is used, then the DC superposition characteristics are insufficient, but using a ferrite inductor improves magnetic properties however it does not have sufficient DC superposition characteristics

Engineering Contradiction:

ImproveDC superposition characteristicsVSAvoidleakage magnetic flux

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The magnetic layer is segmented into a first magnetic layer and a second magnetic layer separated by a non-magnetic layer. This segmentation prevents the formation of a continuous magnetic path through the coil conductor, thereby reducing leakage magnetic flux while maintaining DC superposition characteristics through the composite metal particle structure in each magnetic layer

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A non-magnetic layer is introduced as an intermediary between the first and second magnetic layers. This non-magnetic layer blocks the magnetic flux path that would otherwise leak through the coil conductor, while the metal particles in the magnetic layers maintain the desired DC superposition characteristics

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the size of electronic equipment is reduced, then miniaturization is achieved, but leakage magnetic flux affects other electronic components due to densification

Engineering Contradiction:

Improvesize of coil componentVSAvoidinfluence of leakage magnetic flux on other electronic components

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The magnetic layer is segmented into a first magnetic layer and a second magnetic layer separated by a non-magnetic layer. This segmentation prevents the formation of a continuous magnetic path through the coil conductor, thereby reducing leakage magnetic flux while maintaining DC superposition characteristics through the composite metal particle structure in each magnetic layer

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A non-magnetic layer is introduced as an intermediary between the first and second magnetic layers. This non-magnetic layer blocks the magnetic flux path that would otherwise leak through the coil conductor, while the metal particles in the magnetic layers maintain the desired DC superposition characteristics

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides a coil component with excellent DC superposition characteristics and minimized leakage magnetic flux, suitable for high-current applications in densely packed electronic equipment.

Implementation Method 1

a magnetic layer formed of a composite material including a metal material and a resin material

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a non-magnetic layer is arranged not to extend through a winding portion of the coil conductor or not to extend through the body

Methodology Applied

Scientific EffectMagnetic shielding: Magnetism

Data Source

PatentUS11705271B2Coil component

Publication Date: 2023.07.18 MURATA MFG CO LTD

AI summary

A coil component includes a body and a coil conductor embedded in the body. The body includes a magnetic layer and a non-magnetic layer. The magnetic layer is formed of a composite material including a metal particle and a resin material, and the non-magnetic layer is arranged not to extend through a winding portion of the coil conductor or not to entirely extend through the body.