Magnetic Coil Structure With Adjustable Coupling and High Inductance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing coil components, such as those described in JP 2009-117676A and JP 2016-131208A, face challenges in achieving high inductance and adjusting the coupling coefficient due to their structural limitations, including the use of bar-like coil conductors and non-magnetic materials.

Innovation Solution

A coil component comprising first and second magnetic element bodies with embedded coil conductors, terminal electrodes, and a low-permeability layer between them, allowing for adjustable coupling coefficients and higher inductance by using composite magnetic materials with adjustable permeability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a bar-like coil conductor is used, then the structure is simple, but high inductance cannot be achieved

Engineering Contradiction:

Improvecoil conductor structureVSAvoidinductance value

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent transitions from a simple bar-like conductor to a spiral coil pattern, adding dimensional complexity to the conductor geometry. This spiral configuration increases the effective length and turns of the coil, thereby achieving higher inductance while maintaining manufacturing feasibility through standardized spiral patterns.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent employs a composite structure combining magnetic element bodies with embedded coil conductors. The magnetic material surrounding the spiral coil conductor enhances the inductance by providing magnetic flux concentration, creating a composite system where the combination of magnetic material and spiral conductor achieves higher inductance than either component alone.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If two element bodies are merely bonded to each other, then the structure is simple, but the coupling coefficient cannot be adjusted

Engineering Contradiction:

Improveelement body structureVSAvoidcoupling coefficient adjustability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent introduces a low-permeability layer as an intermediary between the two magnetic element bodies. This intermediate layer acts as a controllable barrier to magnetic flux coupling, allowing the coupling coefficient to be adjusted by modifying the layer's permeability, thickness, or area, without complicating the overall element body structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent enables coupling coefficient adjustment by changing parameters of the low-permeability layer, such as its permeability value, thickness, or lateral dimensions. By varying these parameters, the magnetic coupling between the two element bodies can be precisely controlled, providing adaptability while maintaining a relatively simple bonded structure.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a non-magnetic material is used for the element body, then the structure is simple, but sufficient inductance cannot be obtained

Engineering Contradiction:

Improveelement body materialVSAvoidinductance value

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces non-magnetic element body material with magnetic material, creating a composite structure where the magnetic material serves dual purposes: providing structural support and enhancing magnetic flux concentration. This composite approach achieves sufficient inductance while maintaining structural simplicity through the integrated magnetic element body design.

Inventive Principle:

Principle #40Composite materials

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 proposed coil component achieves high inductance and adjustable coupling coefficients while enhancing withstand voltage between terminal electrodes, addressing the limitations of previous technologies.

Implementation Method 1

a low-permeability layer provided between the first and second magnetic element bodies and being lower in permeability than the first and second magnetic element bodies

Methodology Applied

Scientific EffectMagnetic permeability: Magnetic Field

Implementation Method 2

first and second coil conductors embedded respectively in the first and second magnetic element bodies

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

first and second magnetic element bodies; first and second coil conductors embedded respectively in the first and second magnetic element bodies

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Data Source

PatentUS20240062948A1Coil component

Publication Date: 2024.02.22 TDK CORP

AI summary

Disclosed herein is a coil component that includes, first and second magnetic element bodies, first and second coil conductors embedded respectively in the first and second magnetic element bodies, first and second terminal electrodes exposed from the first magnetic element body and connected respectively to one end and other end of the first coil conductor, third and fourth terminal electrodes exposed from the second magnetic element body and connected respectively to one end and other end of the second coil conductor, and a low-permeability layer provided between the first and second magnetic element bodies and being lower in permeability than the first and second magnetic element bodies.