Layered Coil Component DC Bias Magnetic Saturation
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Solution Overview
Problem
Existing layered coil components for DC-DC converters face challenges in maintaining good DC bias characteristics due to magnetic saturation, which reduces inductance and conversion efficiency, as they often rely on nonmagnetic layers that can lead to excessive magnetic flux and saturation.
Innovation Solution
A layered coil component is designed with a second insulating layer of lower permeability strategically arranged between electrically conductive members, bent to prevent the formation of closed magnetic circuits, thereby reducing magnetic saturation and enhancing DC bias characteristics. This configuration includes a manufacturing method involving press-bonding of insulating layers to ensure the second insulating layer astrides conductive members, increasing magnetic resistance and reducing magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nonmagnetic layer is disposed between magnetic layers to increase magnetic resistance, then magnetic saturation resistance is improved, but closed magnetic circuits are generated that cause excessive magnetic flux density and magnetic saturation
Solution Approach 1:
The second insulating layer is bent at the portion where it is astride the electrically conductive members, creating a curved configuration that prevents formation of closed magnetic circuits. This curvature disrupts the magnetic flux path, preventing excessive magnetic flux density and magnetic saturation while maintaining the magnetic resistance increase benefit.
Solution Approach 2:
The patent uses two different insulating layers with different magnetic permeabilities: a first insulating layer with higher permeability and a second insulating layer with lower permeability. The second layer is strategically positioned and bent at specific locations to create local variations in magnetic properties, preventing closed magnetic circuits only where needed while maintaining overall magnetic circuit efficiency.
2Reliability
If the second insulating layer is arranged to be astride electrically conductive members, then closed magnetic circuits are prevented, but manufacturing complexity increases
Solution Approach 1:
The insulating structure is divided into two distinct segments: a first insulating layer and a second insulating layer with different permeabilities. The second layer is further segmented by being bent at specific portions, creating distinct functional zones that prevent closed magnetic circuits while maintaining manufacturing feasibility through modular layering.
3Reliability
If magnetic resistance is increased to prevent magnetic saturation, then DC bias characteristics improve, but magnetic flux leakage increases
Solution Approach 1:
The patent changes the magnetic permeability parameter by introducing a second insulating layer with lower permeability than the first insulating layer. This parameter change increases magnetic resistance to improve DC bias characteristics while the bent configuration of the second layer controls magnetic flux paths to minimize energy loss through leakage.
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 prevents magnetic saturation, improving DC bias characteristics and maintaining inductance, as demonstrated by reduced rate of change in inductance even under DC bias current, thus enhancing the performance of the layered coil component.
Implementation Method 1
the magnetic resistance of the magnetic paths φ'1 formed around a coil L is increased in the nonmagnetic layer 104
Implementation Method 2
a magnetic flux leaks from the nonmagnetic layer 104
Implementation Method 3
magnetic saturation becomes resistant to occurrence and sharp reduction in the inductance due to the magnetic saturation is suppressed
Data Source
Figure 1
Figure 2
Figure 3A~4
AI summary
DC bias characteristics of an open magnetic circuit type layered coil component are improved. A layered coil component (1) includes a coil that is constructed by layering coil conductor patterns (5) and ceramic sheets. The ceramic sheets include a first ceramic sheet and a third ceramic sheet (4) having a permeability lower than the permeability of the first ceramic sheet. The third ceramic sheet (4) has an arrangement that is astride at least two of the coil conductor patterns (5) adjacent to each other in a layering direction, in a section including a coil axis of the coil (L).