Magnetic Coupling Coil Component Insulation Optimization
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Solution Overview
Problem
Magnetic coupling coil components produced by lamination processes face challenges in achieving high coupling coefficients while ensuring adequate insulation between coil conductors, as leakage magnetic flux causes leakage inductance and potential differences lead to dielectric breakdown.
Innovation Solution
A laminated magnetic coupling coil component design with alternating layers of insulating materials and conductive patterns, where the potential difference between conductive patterns is managed by varying the thickness of insulating layers in different regions, ensuring insulation quality and coupling coefficient through strategically arranged conductive and insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating layer thickness is increased to ensure insulation between coil conductors, then insulation quality is improved, but device profile increases
Solution Approach 1:
The patent implements local quality by varying insulating layer thickness across different regions of the device. Thicker insulating layers are placed only where high potential differences occur (end regions), while thinner insulating layers are used in the intermediate region where coupling is prioritized. This resolves the contradiction between insulation quality and profile thickness by applying insulation enhancement only where necessary.
2Reliability
If coil units are tightly contacted to increase coupling degree, then magnetic coupling is improved, but leakage inductance increases due to leakage magnetic flux
Solution Approach 1:
The patent applies parameter changes by optimizing the spacing and arrangement of coil conductors on adjacent insulating layers. By carefully controlling the lateral positioning and vertical separation of conductors, the patent maximizes magnetic coupling while minimizing leakage flux paths. This resolves the contradiction between coupling coefficient and leakage inductance through precise parameter optimization.
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 a high coupling coefficient between coils while preventing dielectric breakdown, ensuring effective insulation and maintaining a low profile by optimizing the thickness of insulating layers in the intermediate region.
Implementation Method 1
A magnetic coupling coil component includes a pair of coil conductors magnetically coupled to each other
Implementation Method 2
Depending on the directions of the electric current flowing through the coil conductors of both lines, the potential difference is large between the coil conductors arranged on adjacent insulating layers. Therefore, it is difficult to ensure insulation between coil conductors of different lines
Data Source
AI summary
One object of the present invention is to provide a magnetic coupling coil component having a high coupling coefficient between coils of different lines and facilitating insulation between the coils. A coil component according to one embodiment includes: an insulator body including first insulating layers and second insulating layers stacked together in a lamination direction; first conductive patterns formed on the first insulating layers; and second conductive patterns formed on the second insulating layers. The insulator body includes a first end region, a second end region, and an intermediate region positioned between the first end region and the second end region. The first end region includes the first insulating layers only, the second end region includes the second insulating layers only, and the intermediate region includes the first insulating layers and the second insulating layers arranged alternately in the lamination direction.