Laminated Coil Component with Parallel Axis and Insulated Composite Resin
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Solution Overview
Problem
Laminated coil components face challenges in achieving high inductance and maintaining insulation reliability while minimizing size and stray capacitance, with existing designs often compromising inductance due to inclined coil axes and using insulating materials with lower insulation properties.
Innovation Solution
A laminated coil component design where the coil conductor's axis aligns with the lamination direction, with conductor patterns arranged to ensure optimal insulation by varying distances from external electrodes and maintaining parallel magnetic flux direction, using composite resin materials with metal particles for improved magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil axis is inclined with respect to the lamination direction to reduce stray capacitance, then frequency characteristics are improved, but the magnetic path length increases and inductance decreases
Solution Approach 1:
Instead of inclining the coil axis to reduce stray capacitance, the patent inverts the approach by making the coil axis parallel to the lamination direction. This inversion increases stray capacitance slightly but dramatically reduces the magnetic path length, thereby improving inductance. The patent accepts the trade-off of slightly worse frequency characteristics to achieve significantly better inductance performance.
Solution Approach 2:
The patent changes the orientation parameter of the coil axis from inclined to parallel with the lamination direction. This parameter change directly affects the magnetic path length, reducing it from a longer inclined path to a shorter parallel path, thereby increasing inductance while managing the stray capacitance trade-off.
2Quantity of substance
If composite resin materials including metal particles are used to improve magnetic permeability, then inductance increases, but insulation property decreases
Solution Approach 1:
The patent uses composite resin materials including metal particles to achieve high magnetic permeability and improve inductance. The composite structure combines the magnetic properties of metal particles with the insulating properties of the resin matrix, attempting to balance both magnetic performance and insulation requirements.
Solution Approach 2:
The patent introduces an insulating coating as an intermediary layer between the metal particles and the coil conductor. This coating acts as a mediator that prevents direct contact between the conductive metal particles and the coil conductor, thereby maintaining insulation property while still allowing the metal particles to provide their magnetic permeability benefits.
3Volume of moving object
If the coil conductor is reduced in size to minimize the component footprint, then the component size decreases, but the core area is reduced and inductance decreases
Solution Approach 1:
The patent changes the orientation parameter of the coil axis to be parallel with the lamination direction, which optimizes the magnetic path length within the available core area. This parameter change allows the coil to achieve maximum inductance for a given core size, enabling size reduction without proportional inductance loss.
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 design achieves high inductance and excellent insulation reliability by aligning the coil axis with the lamination direction, reducing stray capacitance, and utilizing composite resin materials for enhanced magnetic properties, thus preventing inductance degradation and ensuring effective insulation.
Implementation Method 1
a magnetic flux excited by the laminated coil component has to pass through a core of the laminated coil component along the inclined coil axis
Implementation Method 2
a laminate including a plurality of insulating layers stacked together and a coil conductor embedded in the laminate
Data Source
AI summary
To provide a new type of coil component capable of providing a high inductance and excellent in insulation reliability. A coil component according to one embodiment of the present invention is provided with an insulating body, a first external electrode provided on a surface of the insulating body, a second external electrode provided on a surface of the insulating body, and a coil conductor provided between the first external electrode and the second external electrode. In the coil conductor, a conductor pattern having a larger potential difference from the second external electrode is arranged farther from the second external electrode, and a conductor pattern having a larger potential difference from the first external electrode is arranged farther from the first external electrode.