Isotropic Ferrite Resin Coil Component for Consistent Magnetic Permeability
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Solution Overview
Problem
Existing coil components with laminate structures face challenges in predicting magnetic properties due to differences in magnetic materials, leading to variations in characteristics and potential failures like delamination or cracks, especially in high-speed interfaces where directional sensitivity is a concern.
Innovation Solution
A coil component with an isotropic structure formed by a magnetic resin composite core and cover elements, where a coil conductor is embedded, providing uniform magnetic permeability and improved adhesion through a trapezoidal cross-section design, and a method involving a carrier layer for embedding and bonding the coil conductor within the core element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a laminate structure with ferrite substrate and ferrite resin composite is used, then magnetic properties can be differentiated for specific functions, but magnetic property predictions become difficult and characteristics vary significantly depending on connection direction
Solution Approach 1:
The patent applies homogeneity by making the cover element have the same magnetic properties as the core element (both using ferrite resin composite with similar permeability). This creates a homogeneous magnetic structure that eliminates directional sensitivity and makes characteristic predictions reliable, while still allowing functional differentiation through the coil conductor embedding.
2Stability of the object's composition
If a ferrite substrate formed of brittle ceramic is used, then magnetic properties are stable, but delamination or cracks occur between the insulating layer and the ferrite substrate
Solution Approach 1:
The patent changes the material parameter from brittle ceramic to flexible ferrite resin composite. This material substitution maintains stable magnetic properties through controlled composition while eliminating the brittleness that causes delamination and cracks, thereby improving structural integrity.
Solution Approach 2:
The patent uses composite materials (ferrite powder mixed with resin) to create a core element that combines the magnetic stability of ferrite with the flexibility and adhesion of polymer materials. This composite structure prevents the delamination and cracking issues associated with brittle ceramic substrates.
3Strength
If magnetic powder is dispersed in resin to form ferrite resin composite, then flexibility and adhesion are improved, but magnetic properties become significantly different from ferrite substrate
Solution Approach 1:
The patent creates homogeneity in magnetic properties by designing the cover element to have the same ferrite resin composite composition as the core element. This ensures predictable and consistent magnetic characteristics throughout the component, while the resin matrix provides the necessary adhesion strength.
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 results in consistent coil characteristics regardless of connection direction, improved adhesion, and reduced risk of failures like delamination, enhancing the reliability and predictability of the coil component's performance.
Implementation Method 1
The body of the coil component is an isotropic structure having uniform magnetic permeability as a whole
Implementation Method 2
a coil layer formed on the ferrite substrate
Data Source
AI summary
A coil component may include a core element, a coil conductor embedded in a surface of the core element, and a cover element bonded to the surface of the core element in which the coil conductor is embedded. Since the core element and the cover element are integrally formed, common failures, such as delamination or cracks, may be suppressed, and thereby product reliability may be improved.