Coupled Inductor Coil Structure for Stable Spacing and Coupling
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Solution Overview
Problem
There is a need for a coil electronic component with a coupled inductor structure that can easily adjust the coefficient of coupling (K) while maintaining high inductance, and prevent vertically arranged coils from tilting relative to each other, thereby keeping the spacing between them constant.
Innovation Solution
The coil electronic component includes a first coil, a second coil, an intermediate layer with lower permeability than the magnetic body, and a support structure to maintain alignment and adjust coupling, where the intermediate layer is in contact with or spaced apart from the coils and the magnetic body surrounds both coils and the intermediate layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coupled inductor structure with vertically arranged coils is used to achieve high inductance, then the inductance value increases, but the coils may tilt relative to each other causing variable spacing and coupling coefficient instability
Solution Approach 1:
A support structure is introduced as an intermediary component between the first and second coils. This support maintains a constant distance between the coils, preventing tilting and ensuring stable spacing. The support acts as a mediator that mechanically couples the coils while maintaining their relative positions, thereby stabilizing the coupling coefficient without affecting the high inductance特性.
Solution Approach 2:
The patent adjusts the coupling coefficient by changing the distance between the first and second coils while maintaining their vertical arrangement. By controlling the spacing parameter (through the support structure that prevents unwanted tilting), the coupling coefficient can be tuned independently from the alignment stability issue, allowing optimization of both inductance and coupling characteristics.
2Stability of the object's composition
If a support structure is added to prevent coil tilting and maintain constant spacing, then the alignment stability improves, but the device complexity increases
Solution Approach 1:
The support structure is integrated with the magnetic body, combining two functional elements into a unified component. The magnetic body serves dual purposes: providing magnetic flux paths for coupling and acting as part of the support structure to maintain coil spacing. This merging reduces the number of separate components and simplifies the overall device complexity while maintaining alignment stability.
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 configuration allows for easy adjustment of the coefficient of coupling and prevents tilting, ensuring constant spacing and high inductance, thereby enhancing the efficiency and performance of the coil electronic component.
Implementation Method 1
an intermediate layer disposed from a first region between the first core and the second core to a second region between the first coil and the second coil; and a magnetic body surrounding the first coil, the second coil, and the intermediate layer, wherein the intermediate layer has a smaller permeability than that of the magnetic body
Data Source
AI summary
A coil electronic component includes: a first coil; a second coil spaced apart from the first coil; an intermediate layer disposed to extend from a first region between a first core (hollow space) of the first coil and a second core of the second coil to a second region between the first coil and the second coil; and a magnetic body surrounding the first coil, the second coil, and the intermediate layer, wherein the intermediate layer has a smaller permeability than that of the magnetic body.