Electric Element With Non-Uniform Coil Conductor Thickness
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Solution Overview
Problem
Planar spiral coil components with large aspect ratios formed by electroplating often exhibit nonuniform conductor thickness, leading to significant differences in distance between coil surfaces and the magnet, resulting in inconsistent electromagnetic interactions and characteristic variations between electric elements.
Innovation Solution
The electric element features a substrate with a resin layer and a conductive body having a coil portion with a winding axis orthogonal to the substrate's surface, where the coil conductor has a non-uniform thickness varying along the winding direction, with a smaller difference in distance between the first coil surface and the substrate compared to the second coil surface, reducing variations and enhancing electromagnetic field strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electroplating is used to form planar spiral coil components with large aspect ratios, then the conductor can be formed efficiently, but the conductor thickness becomes nonuniform, leading to significant differences in distance between coil surfaces and the magnet
Solution Approach 1:
The patent applies local quality by creating different conductor thicknesses in different regions of the coil. The conductor is designed with a first thickness in a first region and a second thickness in a second region, allowing each region to have optimized properties for its specific function while maintaining overall manufacturing efficiency through electroplating.
2Ease of manufacture
If the coil conductor has nonuniform thickness, then manufacturing is simplified, but the distance between coil surfaces and the magnet varies significantly, resulting in inconsistent electromagnetic interactions
Solution Approach 1:
The patent resolves this contradiction by implementing local quality with specifically designed thickness variations. The conductor has different thicknesses in different regions, but these variations are controlled and optimized to maintain consistent electromagnetic interactions. The first region has a first thickness and the second region has a second thickness, with each region's thickness optimized for its electromagnetic function.
Solution Approach 2:
The patent applies parameter changes by systematically varying the conductor thickness parameter across different regions. The thickness is changed from a first thickness in the first region to a second thickness in the second region, optimizing electromagnetic interaction consistency while maintaining ease of manufacture through electroplating processes.
3Shape
If the distance between coil surfaces and the magnet varies significantly, then the structure can accommodate thickness variations, but the electromagnetic field strength and driving force are reduced
Solution Approach 1:
The patent applies local quality by creating different conductor thicknesses in different regions of the coil. The conductor is designed with a first thickness in a first region and a second thickness in a second region, allowing each region to have optimized properties for its specific function while maintaining overall manufacturing efficiency through electroplating.
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 stabilizes the characteristics of electric elements by minimizing distance variations between the magnet and the coil surfaces, increasing the electromagnetic field strength and driving force while reducing conductor loss.
Implementation Method 1
the coil portion includes a continuous coil conductor including a first coil surface facing the first principal surface and a second coil surface opposite to the first coil surface
Implementation Method 2
increasing the electromagnetic field strength and driving force
Data Source
AI summary
An electric element includes a substrate including a resin layer and a first conductive body, and a magnet. The substrate includes a first principal surface facing the magnet. The first conductive body includes a coil portion having a winding axis orthogonal to the first principal surface and located on a side closest to the first principal surface. The coil portion includes a continuous coil conductor including a first coil surface facing the first principal surface and a second coil surface opposite to the first coil surface. The coil conductor has a non-uniform thickness in a winding axis direction varying a distance between the first and second coil surfaces, and a difference of maximum and minimum values of distance between the first coil surface and the first principal surface is smaller than a difference of maximum and minimum values of distance between the second coil surface and the first principal surface.