Laminated Coil Component Layout for Insulation Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coil components with metal magnetic particles face reliability issues due to high electric conductivity, leading to short circuits when the insulating film is broken, necessitating improved insulation reliability.
Innovation Solution
A coil component design featuring a base body with a magnetic portion and an insulator of higher insulation quality, where the insulator is strategically placed between conductor patterns and external electrodes to prevent short circuits, thereby enhancing insulation reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal magnetic particles are used in the base body, then magnetic properties are improved, but insulation reliability deteriorates due to high electric conductivity
Solution Approach 1:
The base body is segmented into magnetic portions (containing metal magnetic particles) and insulator portions (resin material) in a laminated structure. This segmentation allows the magnetic portions to provide magnetic properties while the insulator portions provide insulation, preventing short circuits between conductor patterns.
Solution Approach 2:
Different regions of the base body have different properties: magnetic portions are placed where magnetic field generation is needed, while insulator portions are placed where insulation is critical (between conductor patterns and external electrodes). This local differentiation optimizes both magnetic performance and insulation reliability.
2Reliability
If insulator is added between conductor patterns and external electrodes, then insulation reliability is improved, but device complexity increases
Solution Approach 1:
The insulator is merged with the base body itself, forming a laminated structure where magnetic and insulating layers are integrated into a single component. This eliminates the need for separate insulator parts, reducing assembly steps and overall device complexity while maintaining insulation reliability.
Solution Approach 2:
The base body serves multiple functions: it provides magnetic properties through metal magnetic particles, structural support through the laminated architecture, and insulation through resin portions. This multi-functionality reduces the need for additional dedicated insulator components, simplifying the overall device structure.
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 effectively improves insulation reliability by preventing short circuits between the coil conductor and external electrodes, maintaining the saturation flux density and reducing the volume of the magnetic portion, thus enhancing the overall performance of the coil component.
Implementation Method 1
the insulator having a higher insulation quality than the magnetic portion... the insulator is provided between the first conductor pattern and the second external electrode and between the second conductor pattern and the first external electrode
Data Source
AI summary
A coil component includes: a laminate including a magnetic portion and an insulator, the insulator having a higher insulation quality than the magnetic portion; a first external electrode; a second external electrode; and a coil conductor provided in the laminate, wherein the coil conductor includes a plurality of conductor patterns each extending along a planar direction perpendicular to the coil axis, the plurality of conductor patterns being separated from each other in the direction of the coil axis, the plurality of conductor patterns include a first conductor pattern and a second conductor pattern, the first conductor pattern contacting with the first external electrode, the second conductor pattern contacting with the second external electrode, and in the planar direction, the insulator is provided between the first conductor pattern and the second external electrode and between the second conductor pattern and the first external electrode.