Fixed Magnetic Core Coil Structure for Stable Inductance
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Solution Overview
Problem
Existing coil components face challenges in achieving high magnetic permeability while being moldable at low pressure, which is necessary for large-sized coils to maintain stability and inductance.
Innovation Solution
A coil component design that includes a high-permeability magnetic core housed inside the coil and a fixing unit, such as winding end portions, that securely positions the magnetic core within the coil in the axial direction, preventing movement and maintaining magnetic flux stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-permeability magnetic core is used in large-sized coil components, then inductance characteristics are improved, but the component becomes difficult to mold at low pressure
Solution Approach 1:
The magnetic core is divided into two parts: a high-permeability magnetic core for improving inductance characteristics and a low-permeability magnetic material for easy molding. This segmentation allows each part to fulfill its specific function - the high-permeability core provides excellent inductance while the low-permeability material enables low-pressure molding process
Solution Approach 2:
The high-permeability magnetic core is placed inside the coil, which is then embedded in the low-permeability magnetic material. This nested structure allows the high-permeability core to be protected and positioned within the molded component, combining the benefits of high inductance with ease of manufacturing
2Ease of manufacture
If spherical metal magnetic powder with large amount of thermoset resin is used, then low-pressure molding is achieved, but magnetic permeability cannot be achieved
Solution Approach 1:
Different regions of the magnetic core have different magnetic permeability properties. The portion that requires high magnetic permeability (for inductance) is made from high-permeability magnetic core material, while the portion that requires ease of molding is made from low-permeability magnetic material with spherical metal powder and thermoset resin
Solution Approach 2:
The magnetic core is constructed as a composite of two different magnetic materials: a high-permeability magnetic core material and a low-permeability magnetic material containing spherical metal powder and thermoset resin. This composite structure allows the component to achieve both low-pressure molding capability and high magnetic permeability where needed
3Stability of the object's composition
If high-permeability magnetic core is positioned at coil central core portion, then inductance stability is improved, but positioning becomes difficult without exposure on surface
Solution Approach 1:
The low-permeability magnetic material acts as an intermediary substance that fills the space between the high-permeability magnetic core and the mold cavity. This intermediary material allows the high-permeability core to be positioned at the coil central core portion for optimal inductance stability while being completely embedded and protected within the molded component
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 allows for the stabilization of inductance without altering the magnetic flux flow, enabling the production of large-sized coil components with excellent inductance characteristics and reduced manufacturing costs.
Implementation Method 1
compounding a relatively large amount of thermoset resin which melts at about 100° C. or more, and molding the compound at a temperature equal to or more than a melt temperature of the resin
Implementation Method 2
a high-permeability magnetic core molded and fired in advance
Data Source
AI summary
A coil component includes a coil, a magnetic core which is housed inside the coil, and a fixing unit which fixes the magnetic core to the coil such that the magnetic core is located within the coil in an axial direction. The coil is configured to include a winding wire which extends helically. The magnetic core has a high magnetic permeability and is housed in a central core portion which is inside the coil.