Embedded Coil Structure for Lower Magnetic Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components with embedded coil parts in magnetic element bodies experience increased magnetic resistance at bent parts due to abrupt field bending, limiting their inductance.
Innovation Solution
A coil component design where the coil part's height decreases toward the inner diameter area, with a magnetic element body comprising regions that connect and cover the coil part from both sides, reducing magnetic resistance by increasing the angle of the magnetic field bend and ensuring higher inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil part has a substantially constant height in the coil axis direction, then the manufacturing process is simple, but the magnetic field is abruptly bent resulting in increased magnetic resistance
Solution Approach 1:
The coil part is designed with variable height in different regions: the outer diameter area maintains a first height for simple manufacturing, while the inner diameter area has a second height (different from the first) to control magnetic field bending. This local differentiation resolves the contradiction by optimizing each region for its specific function.
Solution Approach 2:
The invention introduces height variation as an additional dimensional parameter to control magnetic field behavior. By making the height in the inner diameter area different from the outer diameter area, the magnetic field bending is softened rather than abrupt, reducing magnetic resistance while maintaining manufacturing feasibility.
2Object-affected harmful factors
If the height of the coil part is reduced toward the inner diameter area, then magnetic resistance is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The coil part is segmented into two distinct height regions: an outer diameter area with a first height and an inner diameter area with a second height. This segmentation allows the complex height variation to be implemented in a controlled manner, reducing overall structural complexity while achieving the magnetic resistance reduction goal.
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 reduces magnetic resistance at bent parts and increases inductance by alleviating magnetic field concentration, achieving higher inductance through a manufacturing method that deforms the coil part using water pressure and magnetic element body formation.
Implementation Method 1
a magnetic element body and a coil part embedded in the magnetic element body
Implementation Method 2
reducing magnetic resistance by increasing the angle of the magnetic field bend
Implementation Method 3
a coil part embedded in the magnetic element body
Data Source
AI summary
Disclosed herein is a coil component that includes a magnetic element body, and a coil part embedded in the magnetic element body. The magnetic element body includes a first region covering the coil part from one side in a coil axis direction, a second region covering the coil part from other side in the coil axis direction, and a third region positioned in an inner diameter area of the coil part so as to connect the first and second regions. The height of the coil part in the coil axis direction decreases toward the inner diameter area.