Curved Insulating Gap Layer in Magnetic Resin Coil Components
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Solution Overview
Problem
The existing coil components with embedded coil patterns in magnetic resin layers face challenges in reducing height without causing cracks or increasing material costs, as they require two magnetic substrates which are difficult to thin without compromising reliability.
Innovation Solution
A coil component design that eliminates the need for magnetic substrates by using first and second magnetic resin layers with an insulating gap layer between them, where the insulating gap layer is curved to enhance adhesion and function as a magnetic gap, allowing for reduced material costs and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two magnetic substrates are used to embed the coil pattern, then the coil component achieves structural stability and magnetic gap function, but the height cannot be reduced and material cost increases
Solution Approach 1:
The patent extracts the magnetic substrate from the structure and replaces it with magnetic resin layers. The first and second magnetic resin layers are formed on opposite surfaces of the insulating gap layer, eliminating the need for traditional magnetic substrates while maintaining the magnetic circuit functionality and reducing overall height.
Solution Approach 2:
The patent uses composite magnetic resin materials that combine magnetic particles with resin matrices to create the first and second magnetic resin layers. These composite materials provide both magnetic functionality and structural support, replacing traditional magnetic substrates and enabling height reduction while maintaining reliability.
2Reliability
If two magnetic substrates are used to embed the coil pattern, then the coil component achieves magnetic gap function, but material cost increases
Solution Approach 1:
The patent extracts the expensive magnetic substrate material and replaces it with more cost-effective magnetic resin materials. The insulating gap layer itself serves as the magnetic gap structure, eliminating the need for additional magnetic substrate materials while maintaining the magnetic gap function.
Solution Approach 2:
The insulating gap layer performs multiple functions: it provides electrical insulation, creates the magnetic gap, and serves as the base structure for forming the first and second magnetic resin layers. This multi-functionality eliminates the need for separate magnetic substrates, reducing material cost while maintaining functionality.
3Length of stationary object
If the magnetic substrate is made thinner to reduce height, then the height is reduced, but crack or chipping occurs reducing product reliability
Solution Approach 1:
The patent uses composite magnetic resin materials with appropriate thickness that provide both height reduction and structural integrity. The magnetic resin layers can be formed at optimized thicknesses that avoid the crack and chipping issues associated with thinning traditional magnetic substrates, maintaining product reliability while achieving height reduction.
Solution Approach 2:
The patent changes the material parameters from traditional magnetic substrates to magnetic resin materials, allowing for optimized thickness and mechanical properties. This parameter change enables achieving the desired height reduction without compromising structural strength and reliability.
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 achieves a reliable and cost-effective coil component with enhanced adhesion and mechanical strength by eliminating the need for magnetic substrates and optimizing the material usage, while maintaining the structural integrity and functionality of the coil pattern.
Implementation Method 1
the insulating gap layer is provided between the first and second magnetic resin layers, allowing the insulating gap layer to function as a magnetic gap
Implementation Method 2
the insulating gap layer is curved in the axial direction, so that a contact area between the insulating gap layer and the first and second magnetic resin layers is increased to enhance adhesion therebetween
Data Source
AI summary
A coil component includes: a first magnetic resin layer in a lower area; a second magnetic resin layer in an inner diameter area surrounded by a coil pattern, an outer peripheral area that surrounds the coil pattern, and an upper area; and an insulating gap layer between the first and second magnetic resin layers. A part of the insulating gap layer positioned between the first magnetic resin layer and a part of the second magnetic resin layer positioned in the inner diameter area is curved in the axial direction. A magnetic substrate need not be used. The insulating gap layer is provided, allowing the insulating gap layer to function as a magnetic gap. The insulating gap layer is curved in the axial direction, so that a contact area between the insulating gap layer and the first and second magnetic resin layers are increased to enhance adhesion therebetween.