DC-DC Converter Multilayer Coil Array Insulation
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Solution Overview
Problem
In small-sized surface-mount coil array components, a potential difference between coils can lead to a risk of short circuits between adjacent coil conductors, necessitating a solution to reduce this potential difference and prevent short circuits.
Innovation Solution
A DC-DC converter multilayer coil array design that includes a magnetic layer, non-magnetic layer, and specific outer electrode connections to reduce the potential difference between adjacent coil conductors, with end portions of the coils connected to a capacitor to suppress short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small-sized surface-mount coil array component is used, then the device size is reduced, but the potential difference between adjacent coil conductors increases causing short circuit risk
Solution Approach 1:
A non-magnetic layer is introduced as an intermediary substance between adjacent coil conductors in the multilayer coil array. This non-magnetic layer acts as an insulating barrier that reduces the potential difference between adjacent coils, preventing short circuits while allowing the device to maintain its small size. The non-magnetic layer is positioned between the first coil and second coil, serving as a protective mediator that eliminates the harmful electrical interaction between adjacent conductors.
2Area of stationary object
If coil conductors are placed close together to reduce device size, then the device becomes more compact, but the insulation between adjacent coils deteriorates
Solution Approach 1:
The multilayer coil array employs a composite structure combining magnetic layers (for inductance function) and non-magnetic layers (for insulation function). This composite material approach allows adjacent coils to be placed in close proximity while maintaining adequate insulation. The non-magnetic layer, positioned between the magnetic layers containing the coil conductors, provides electrical isolation that prevents short circuits even when the device footprint is minimized.
3Reliability
If adjacent coils are connected to reduce potential difference, then short circuit risk decreases, but the device complexity increases
Solution Approach 1:
The non-magnetic layer is integrated into the multilayer structure itself, merging the insulation function with the coil array construction. Rather than adding separate connection structures or external insulation components, the non-magnetic layer is built-in between the magnetic layers during the manufacturing process. This merging approach provides short circuit suppression while maintaining a simple, unified device structure.
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 design effectively reduces the potential difference between adjacent coil conductors and prevents short circuits, enhancing the reliability of the DC-DC converter by increasing insulation and coupling coefficients between coils.
Implementation Method 1
A non-magnetic layer is provided between the first coil and the second coil
Data Source
AI summary
A multilayer coil array includes an element body; first and second built-in coils; and first to fourth outer electrodes provided on the element body. A non-magnetic layer is provided between the first and second coils. An end of the first coil extending from the coil conductor closest to the second coil among the plurality of coil conductors of the first coil is connected to the first outer electrode and another end of the first coil is connected to the second outer electrode. An end of the second coil extending from the coil conductor closest to the first coil among the plurality of coil conductors of the second coil is connected to the third outer electrode and another end portion of the second coil is connected to the fourth outer electrode. The second and fourth outer electrodes are connected to output terminals of a switching element of a DC-DC converter.