Flat-Particle Coil Component for High-Permeability Wireless Circuits

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Solution Overview

Problem

Existing coil components with high aspect ratio coil patterns face difficulties in enhancing the permeability of magnetic layers due to the challenge of magnetic particles entering between radially adjacent turns, and spherical magnetic particles do not effectively improve permeability.

Innovation Solution

A coil component with a flat coil pattern and a magnetic layer composed of flat-shaped magnetic particles dispersed in resin, where the magnetic particles are oriented horizontally to enhance permeability and reduce parasitic capacitance, allowing them to be easily positioned between coil turns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If spherical magnetic particles are used to facilitate entering between coil turns, then ease of manufacture is improved, but magnetic permeability cannot be enhanced

Engineering Contradiction:

Improveease of manufactureVSAvoidmagnetic permeability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the shape parameter of magnetic particles from spherical to flat-shaped (platelet or flake shape). This parameter change enables the particles to orient horizontally and enter between radially adjacent coil turns more effectively, thereby enhancing magnetic permeability while maintaining ease of manufacture through direct paste application.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite magnetic layer formed by dispersing flat-shaped magnetic particles in a resin binder. This composite structure allows the magnetic particles to be held in a horizontal orientation within the layer, enabling them to effectively enter between coil turns and enhance permeability, while the resin provides structural support and ease of application.

Inventive Principle:

Principle #40Composite materials

2Area of stationary object

If high aspect ratio coil pattern is used, then space utilization is improved, but magnetic particles cannot enter between radially adjacent turns

Engineering Contradiction:

Improvespace utilizationVSAvoidmagnetic particle penetration

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The invention changes the shape parameter of magnetic particles from spherical to flat-shaped with horizontal orientation capability. This allows the particles to enter between radially adjacent turns of high aspect ratio coil patterns by lying flat horizontally, overcoming the penetration difficulty while maintaining the space-efficient high aspect ratio coil design.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces a horizontal dimension for magnetic particle orientation within the magnetic layer. By orienting flat-shaped particles horizontally (parallel to the substrate surface), they can effectively span and enter between radially adjacent coil turns, adding a dimensional solution to the penetration problem without altering the coil pattern geometry.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 configuration enhances the magnetic permeability and reduces parasitic capacitance, enabling efficient signal transmission and reception at frequencies of 10 MHz or more, maintaining high-quality magnetic properties and self-resonant frequency.

Implementation Method 1

a magnetic layer comprising a composite material obtained by dispersing magnetic particles in resin and formed on the one surface of the substrate so as to cover the coil pattern. Each of the magnetic particles has a flat shape in which a thickness in a direction perpendicular to the one surface of the substrate is smaller than a diameter in a direction parallel to the one surface of the substrate, and some of the magnetic particles exist within a height range of the coil pattern

Methodology Applied

Scientific EffectMagnetic permeability enhancement: Ferromagnetism

Data Source

PatentUS11804654B2Coil component and wireless communication circuit using the same

Publication Date: 2023.10.31 TDK CORP

AI summary

Disclosed herein is a coil component that includes a substrate, a coil pattern formed on one surface of the substrate, and a magnetic layer comprising a composite material obtained by dispersing magnetic particles in resin and formed on the one surface of the substrate so as to cover the coil pattern. The coil pattern has a flat shape in which a thickness thereof is smaller than a radial width. Each of the magnetic particles has a flat shape in which a thickness thereof in a direction perpendicular to the one surface of the substrate is smaller than a diameter in a direction parallel to the one surface of the substrate. Some of the magnetic particles exist within a height range of the coil pattern with respect to the one surface of the substrate.