Laminated Coil Component Grain Diameter Control for High Frequency Q Value
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Solution Overview
Problem
Laminated coil components have a low Q value compared to wound coils due to their structure and manufacturing methods, making them inadequate for high-frequency applications.
Innovation Solution
Improving the surface smoothness of coil conductors by setting the grain diameter to 10 μm to 22 μm after baking, and using a glass-ceramic composition with 86.7 weight % to 92.5 weight % SiO2 and 0.5 weight % to 2.4 weight % Al2O3, along with a potassium coating layer to reduce surface resistance and prevent metal melting during baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the grain diameter of the coil conductor is increased to reduce surface roughness, then surface resistance decreases and Q value improves, but manufacturing precision becomes difficult to control
Solution Approach 1:
The patent specifies a precise grain diameter range (10 μm to 22 μm) as a critical manufacturing parameter. This parameter control approach transforms the abstract goal of 'improving surface smoothness' into a quantifiable and controllable specification. By defining this specific range, the patent provides clear manufacturing guidelines that balance Q value improvement with manufacturability, resolving the contradiction between performance optimization and manufacturing precision.
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
Achieves a high Q value while ensuring the quality and preventing open circuits or pull-in issues, enabling the laminated coil component to perform effectively at high frequencies.
Implementation Method 1
When surface resistance of a coil conductor is large at a high frequency, a Q value cannot be increased due to a skin effect
Implementation Method 2
an element assembly made from glass-ceramic. Accordingly, dielectric constant of the element assembly can be decreased and a Q value can be increased
Data Source
AI summary
In the laminated coil component, the grain diameter of the coil conductors is 10 μm to 22 μm after baking is completed. When the grain diameter of the coil conductors is set to be 10 μm or larger after baking is completed, surface roughness of the coil conductors can be reduced to such an extent that a satisfactory Q value can be obtained at a high frequency. In addition, when the grain diameter of the coil conductors is set to be 22 μm or smaller after baking is completed, metal of the coil conductors can be refrained from being rapidly melted down during baking. Accordingly, a high Q value can be obtained while a high quality is ensured.