Magnetic Coupling Coil Structure Balancing Coupling and Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic coupling coil components have limitations in achieving a high coupling coefficient between coil conductors, primarily due to the insulator bodies not containing electrically conductive filler particles, which restricts their magnetic permeability.
Innovation Solution
The proposed magnetic coupling coil component incorporates insulator bodies with electrically conductive filler particles, enhancing their magnetic permeability. The coil conductors in each insulator body are wound around a coil axis with specific turns and intervals, and the distance between the coil surfaces is optimized to ensure effective magnetic coupling while preventing dielectric breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulator bodies are formed of conventional ferrite without electrically conductive filler particles, then insulation is maintained, but magnetic permeability is limited and coupling coefficient is reduced
Solution Approach 1:
The insulator body is formed as a composite material containing both ferrite particles and electrically conductive filler particles (such as iron powder or nickel powder). This composite structure simultaneously provides the magnetic permeability needed for high coupling coefficient and the electrical conductivity required for sufficient insulation strength, resolving the contradiction between these two requirements.
Solution Approach 2:
The invention changes the physical and chemical parameters of the insulator body by incorporating electrically conductive filler particles with specific conductivity values (10^-6 to 10^-3 S/m) and controlling their concentration (1-50 wt%). This parameter modification enables the insulator to achieve both high magnetic permeability and adequate insulation strength, thereby improving the coupling coefficient while preventing dielectric breakdown.
2Reliability
If electrically conductive filler particles are added to insulator bodies, then magnetic permeability and coupling coefficient improve, but dielectric breakdown risk may increase
Solution Approach 1:
The invention optimizes the concentration of electrically conductive filler particles within a specific range (1-50 wt%). This controlled parameter adjustment ensures that the magnetic permeability and coupling coefficient are sufficiently improved while the insulation strength remains adequate to prevent dielectric breakdown, thus resolving the contradiction between these competing requirements.
Solution Approach 2:
The electrically conductive filler particles are distributed throughout the insulator body to locally enhance magnetic permeability in regions where magnetic flux passes through, while the overall composite structure maintains sufficient insulation strength. This local quality enhancement resolves the contradiction between improving coupling and maintaining insulation.
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
This configuration results in a higher coupling coefficient between the coil conductors compared to conventional components, while ensuring adequate insulation to prevent dielectric breakdown, thus enhancing the overall performance of the magnetic coupling coil component.
Implementation Method 1
the first insulator body contains the first filler particles at least partially having electrical conductivity, and therefore, the first insulator body has a higher magnetic permeability than a conventional insulator body formed of ferrite and not containing electrically conductive filler particles
Data Source
AI summary
A coil component according to one embodiment of the present invention includes: a first insulator body containing first magnetic metal particles; a second insulator body containing second magnetic metal particles; a first coil conductor provided in the first insulator body and wound around a coil axis for N1 turns such that intervals between adjacent turns are g1; and a second coil conductor provided in the second insulator body and wound around the coil axis for N2 turns such that intervals between adjacent turns are g2. In the embodiment, a first coil surface of the first coil conductor faces a second coil surface of the second coil conductor, and a distance T between the first coil surface and the second coil surface satisfies a relationship T≥g1×N1+g2×N2.