Sintered Ferrite Coil Component for Adjustable Magnetic Coupling
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Solution Overview
Problem
Existing coil arrays with substrates lacking magnetic characteristics, such as printed circuit boards, exhibit low flexibility in adjusting the coupling coefficient between coils, resulting in insufficient coupling.
Innovation Solution
A coil component utilizing a support substrate made of sintered ferrite with a thickness of 40 μm to 80 μm, embedded with magnetic portions, allowing for flexible adjustment of the coupling coefficient between coils by optimizing the magnetic permeability ratio of the substrate and magnetic portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a substrate with no magnetic characteristics (e.g., printed circuit board) is used, then the structure is simple and easy to manufacture, but the coupling coefficient between coils cannot be adjusted flexibly and coupling is insufficient
Solution Approach 1:
The patent uses a composite substrate structure combining ferrite magnetic material and resin material. The ferrite powder (70-90 wt%) provides magnetic characteristics for adjustable coupling, while the resin (10-30 wt%) provides structural support and ease of processing. This composite approach achieves both magnetic functionality and manufacturing simplicity.
Solution Approach 2:
The patent adjusts the magnetic permeability of the substrate by controlling the ferrite powder content, particle size distribution, and sintering conditions. By changing these parameters, the substrate's magnetic characteristics are optimized to achieve flexible coupling coefficient adjustment while maintaining structural integrity.
2Reliability
If the substrate thickness is increased to improve coupling, then coupling efficiency improves, but the overall size of the coil component increases
Solution Approach 1:
The patent creates local magnetic field concentration by distributing ferrite powder non-uniformly within the substrate, with higher concentration in regions where magnetic coupling is most needed. This allows effective coupling with optimized thickness by enhancing magnetic properties locally rather than uniformly throughout the entire substrate.
Solution Approach 2:
The patent uses ferrite powder particles as discrete magnetic elements distributed throughout the substrate, effectively creating a distributed magnetic field structure that achieves coupling efficiency similar to thicker solid ferrite substrates but with reduced overall thickness and improved flexibility.
3Adaptability or versatility
If ferrite powder content in the substrate is increased to enhance magnetic characteristics, then coupling adjustability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent optimizes ferrite powder content within a specific range (70-90 wt%) to achieve sufficient magnetic characteristics without excessive complexity. The particle size is controlled (0.1-10 μm) to ensure proper distribution during mixing and sintering, balancing magnetic performance with manufacturing feasibility.
Solution Approach 2:
The patent applies different ferrite powder concentrations in different regions of the substrate corresponding to different coupling requirements. This localized optimization allows magnetic characteristic adjustment where needed while using less ferrite powder overall, reducing manufacturing complexity and cost.
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 use of sintered ferrite as a substrate enhances the flexibility in adjusting the coupling coefficient between coils, improving coupling efficiency within a specific range, facilitating precise tuning of the coupling coefficient.
Implementation Method 1
the magnetic permeability μ1 of the magnetic portion is about 20 or more and 40 or less... the ratio of the magnetic permeability μ2 of the support substrate to the magnetic permeability μ1 of the magnetic portion is about 0.7 or less
Data Source
AI summary
A coil component including an element assembly that includes a support substrate having a cavity, a first coil disposed on a first principal surface of the support substrate, a second coil disposed on a second principal surface of the support substrate, and a magnetic portion. The coil component further includes first and second outer electrodes electrode electrically coupled to the first coil, and third and further outer electrodes electrically coupled to the second coil. Each outer electrode is disposed on the surface of the element assembly. The cavity of the support substrate, the core portion of the first coil, and the core portion of the second coil overlap at least one another when viewed in the direction perpendicular to the principal surface. The magnetic portion is disposed in at least the cavity and the two core portions. Also, the support substrate is formed of sintered ferrite.