Laminated Coil Component Reducing DC Resistance
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Solution Overview
Problem
Existing coil components for power supply circuits face a trade-off between reducing DC resistance and maintaining sufficient inductance, with those designed for signal transmission being unsuitable due to high DC resistance and low connection reliability when handling high currents.
Innovation Solution
A coil component with a laminated structure of conductor and non-magnetic insulating layers, where the conductor layers are connected through holes in the insulating layers to form a coil pattern, and external terminals are positioned to avoid covering magnetic members, allowing for reduced DC resistance while ensuring inductance and increased self-resonance frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the coil length is reduced and the cross-sectional area of the coil conductor is increased to reduce DC resistance, then the DC resistance decreases, but the inductance becomes insufficient
Solution Approach 1:
The patent transitions from a planar coil structure to a three-dimensional laminated structure with multiple conductor layers stacked vertically. This dimensional change allows the coil to achieve both low DC resistance (through increased effective conductor cross-section via multiple layers) and sufficient inductance (through maintained loop area in the horizontal plane), resolving the trade-off between these two parameters.
Solution Approach 2:
The patent employs a composite structure consisting of multiple conductor layers separated by non-magnetic insulating layers. This composite approach enables the coil to simultaneously achieve low DC resistance (through parallel current paths in multiple conductor layers) and sufficient inductance (through the maintained geometric configuration), as the insulating layers prevent short circuits while allowing magnetic flux penetration.
2Loss of energy
If a conductive pattern is formed on the surface of a laminated insulating layer to reduce DC resistance, then the DC resistance decreases, but the connection reliability deteriorates
Solution Approach 1:
The patent moves the conductive pattern from a surface configuration to a multi-layer volumetric structure. By stacking multiple conductor layers and connecting them through vertical conductive paths, the design achieves low DC resistance through increased effective conductor area while maintaining connection reliability through robust three-dimensional interconnections rather than surface patterns.
3Ease of manufacture
If magnetic members are covered by external terminals to simplify terminal formation, then the manufacturing process is simplified, but the self-resonance frequency decreases
Solution Approach 1:
The patent extracts the external terminals from the magnetic members, positioning them separately on the coil structure. This separation allows the external terminals to be formed independently without covering the magnetic members, thereby maintaining high self-resonance frequency (by avoiding magnetic material coverage that would lower resonance) while still achieving simplified terminal formation through the modular 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 reduces DC resistance while maintaining sufficient inductance, enhances self-resonance frequency, and facilitates easy terminal formation, making it suitable for high-current applications with improved connection reliability.
Implementation Method 1
The insulating layers interposed between the conductor layers are each made of a non-magnetic material, so that a self-resonance frequency of the coil component can be increased
Implementation Method 2
The conductor layers are connected to each other through through holes formed in the non-magnetic insulating layers to constitute a coil pattern
Data Source
AI summary
Disclosed herein is a coil component that includes first and second magnetic members; a coil layer arranged between the first and second magnetic members, the coil layer including a plurality of conductor layers and a plurality of non-magnetic insulating layers, the conductor layers and the non-magnetic insulating layers being alternately laminated, the conductor layers being connected to each other via through holes formed in the non-magnetic insulating layers to form a coil pattern; a first external terminal covering one end of the coil pattern exposed to at least one of side surfaces of the coil layer without covering the first and second magnetic members; and a second external terminal covering other end of the coil pattern exposed to at least one of the side surfaces of the coil layer without covering the first and second magnetic members.