Coil Component Square Cross-Section Alignment
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Solution Overview
Problem
The challenge lies in simplifying the chip alignment process and improving inductance characteristics of coil components with equal width and thickness, as conventional designs require separate processes for distinguishing width and thickness directions, leading to increased complexity and potential errors.
Innovation Solution
The proposed coil component design includes a body with a hexahedral shape, a substrate, a coil unit, external electrodes, and a cover portion, where the cross-section in the width and thickness directions has the same size, allowing for simplified alignment and improved inductance characteristics by using magnetic composite sheets and insulating resin, and eliminating the need for separate chip alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coil component has equal width and thickness dimensions, then the chip alignment process becomes simpler and productivity improves, but the inductance characteristics may deteriorate due to reduced magnetic material volume
Solution Approach 1:
The patent uses magnetic composite sheets consisting of magnetic particles dispersed in an insulating resin matrix. This composite structure allows the magnetic material to be formed into thin layers with high magnetic permeability, enabling the coil component to achieve sufficient inductance even with equal width and thickness dimensions. The composite material provides both the necessary magnetic properties and structural flexibility to maintain the square cross-section shape.
Solution Approach 2:
The patent optimizes the magnetic path by utilizing the length dimension (L-direction) to provide sufficient magnetic flux path length, compensating for the reduced width and thickness. The coil unit is configured to extend along the length direction, ensuring that the magnetic circuit has adequate path length for achieving target inductance values despite the compact width-thickness cross-section.
2Device complexity
If the coil component has equal width and thickness dimensions, then manufacturing complexity is reduced, but the magnetic material volume available for inductance generation is limited
Solution Approach 1:
The magnetic composite sheets enable high magnetic particle concentration within the available volume, maximizing the magnetic material content density. The insulating resin matrix allows for efficient packing of magnetic particles, achieving high magnetic permeability in a compact volume suitable for equal width-thickness dimensions.
Solution Approach 2:
The patent compensates for limited width-thickness cross-sectional area by extending the magnetic path length in the length direction. The coil structure is designed to utilize the length dimension effectively, providing sufficient magnetic flux path length to achieve adequate inductance despite the constrained cross-sectional area.
3Ease of manufacture
If conventional coil components with equal width and thickness are used, then no separate chip alignment process is needed, but the inductance characteristics and reliability are compromised
Solution Approach 1:
The magnetic composite sheets provide the necessary magnetic properties in a thin-layer format that enables the coil component to achieve sufficient inductance with equal width and thickness dimensions. The high magnetic permeability of the composite material compensates for the reduced volume, maintaining reliability while enabling simplified manufacturing.
Solution Approach 2:
The coil unit configuration extends along the length direction to provide adequate magnetic path length, ensuring sufficient inductance generation capability. This dimensional optimization allows the component to maintain equal width-thickness cross-section while achieving target inductance values through extended path length in the third dimension.
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 simplifies the chip alignment process and enhances inductance characteristics by maintaining equal width and thickness dimensions, improving component reliability and productivity while maintaining effective electrical performance.
Implementation Method 1
using magnetic composite sheets and insulating resin
Data Source
AI summary
A coil component includes a body having a first surface and a second surface opposing in a thickness direction, and a first side surface and a second side surface opposing in a width direction while each connecting the first surface and the second surface to each other. A coil unit is disposed in the body. First and second external electrodes are disposed to be spaced apart from each other on the body, while respectively being connected to the coil unit. A cover portion disposed on the second surface of the body and at least partially covering the first and second external electrodes. A cross-section perpendicular to the first surface of the body and parallel to the width direction and traversing the body and the cover portion has substantially the same size in the width direction and in the thickness direction.