Coupled Coil Layout for Inductance Control in Thin Components
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Solution Overview
Problem
The challenge in miniaturizing and thinning coil components while maintaining their characteristics is compounded by the need to control coupling inductance and characteristic deviations between coil portions in coupled inductor structures.
Innovation Solution
The proposed coil component design includes a body with specific surface orientations, a support member, and coils with distinct core configurations. The first coil has a first core with a shared and non-shared portion, while the second coil has a second core with overlapping and non-overlapping areas. This design allows for adjustable coupling coefficients by varying the relative area ratios of shared and non-shared cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ratio of magnetic material in core is increased to maintain characteristics during miniaturization and thinning, then the inductor characteristics are maintained, but the body strength decreases and frequency characteristics deteriorate due to insulation property changes
Solution Approach 1:
The core is divided into first core and second core with different magnetic material filling ratios. The first core has a higher magnetic material filling ratio to maintain inductor characteristics, while the second core has a lower ratio to preserve body strength and insulation properties. This segmentation allows each core region to optimize for its specific function without compromising the other.
2Area of stationary object
If coupled inductor structure is used to reduce mounting area, then mounting area is reduced, but coupling inductance control and characteristic deviation between coil portions become problematic
Solution Approach 1:
Different regions of the core are assigned different magnetic material filling ratios to achieve local optimization. The first core region has higher magnetic material content for strong magnetic coupling, while the second core region has lower magnetic material content for mechanical support and insulation. This local quality differentiation enables precise control of coupling inductance while maintaining manufacturing feasibility.
3Loss of energy
If coupling coefficient is increased to decrease inductor current ripple, then inductor current ripple is decreased and efficiency is improved, but the design becomes more constrained for applications requiring smaller coupling coefficients
Solution Approach 1:
The coupled inductor structure with different magnetic material filling ratios creates a flexible magnetic coupling system where the coupling coefficient can be dynamically adjusted by changing the relative positions and orientations of the first and second cores. This dynamic configuration allows the same structure to serve applications requiring both high and low coupling coefficients.
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 effective control of coupling inductance and characteristic deviations between coil portions, enhancing the efficiency and reducing the mounting area requirements of inductor arrays without increasing their size.
Implementation Method 1
the first core partially overlaps the second core when viewed in the third direction of the body
Data Source
AI summary
A coil component includes: a body; a support member disposed inside the body and having one surface and another surface opposing each other; a first coil disposed on the one surface of the support member and including a first core; a second coil disposed on the other surface of the support member and including a second core; a first lead portion disposed on the other surface of the support member and connected to the first coil; and a second lead portion disposed on the one surface of the support member and connected to the second coil, in which the first core partially overlaps the second core when viewed in a stacking direction of the first and second coils on the support member, and a length of the second coil in one direction is larger than a length of the first coil in the one direction.