Flexible Coil Component with Anisotropic Magnetic Sheet
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Solution Overview
Problem
Conventional coil components used in power supply circuits for mobile devices are brittle and prone to breakage due to flexure or shock, and they require higher inductance values to meet the increasing demands of smaller, more powerful devices.
Innovation Solution
A coil component with an air core coil spirally formed in a planar state, layered with an anisotropic compound magnetic sheet composed of flat or needle-shaped soft magnetic metal powder dispersed in a resin, and filled with isotropic or anisotropic compound magnetic materials to enhance magnetic permeability and inductance, while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional inductor with laminated ferrite sintered bodies is used, then the inductance value can be achieved, but the core body becomes brittle and fragile against bending and shock impact
Solution Approach 1:
The patent changes the material parameters from brittle ferrite sintered bodies to flexible resin-based compound magnetic sheets, fundamentally altering the mechanical properties while maintaining magnetic functionality. This allows the inductor to bend and deform without breaking, solving the brittleness problem.
Solution Approach 2:
The patent uses composite materials consisting of magnetic powder dispersed in a resin matrix to create compound magnetic sheets. This composite structure combines the magnetic properties needed for inductance with the flexibility and shock resistance of the resin, eliminating the brittleness of conventional ferrite cores.
2Ease of manufacture
If isotropic magnetic powder is dispersed in resin, then manufacturing is simplified, but the magnetic permeability and inductance value are insufficient
Solution Approach 1:
The patent introduces directional orientation of magnetic powder particles within the resin matrix. By creating regions with specific particle orientations aligned with the magnetic flux paths, the magnetic permeability is enhanced while maintaining a relatively simple manufacturing process using conventional dispersion techniques.
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 solution improves the inductance value and mechanical resilience of the coil component, allowing it to deform with flexible printed boards and withstand drop shocks, while maintaining excellent direct-current characteristics.
Implementation Method 1
the magnetic permeability of a compound magnetic sheet according to the direction in which a magnetic flux radiated by the inductor passes
Implementation Method 2
the direction in which a magnetic flux radiated by the inductor passes
Implementation Method 3
the major axis of the soft magnetic metal powder orients toward an in-plane direction of the air core coil having flexibility
Implementation Method 4
being dispersed in a resin material
Data Source
AI summary
A coil component is provided, and the coil component for an inductor is deformable dependent on flex of a flexible printed board due to elapse of time when mounted thereon, and has high resistance against dropping impact and has an inductance value. The coil component includes an anisotropic compound magnetic sheet which is layered on at least any one or both of the upper surface and the lower surface of an air core coil formed spirally in a plane and which is composed of flat or needle-shaped soft magnetic metal powder, which has a major axis and a minor axis and is dispersed in a resin material, the major axis of which corresponds to an in-plane direction of the air core coil.