Magnetic Layer Coil Component for Higher Inductance in Less Space
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Solution Overview
Problem
In the development of compact electronic devices, existing coil components face challenges in achieving improved inductance properties, reduced size, and increased saturation magnetization values while maintaining performance, particularly in reducing the number of coil turns and enhancing Rdc and Isat properties.
Innovation Solution
A coil component design that includes a body with a coil, a first insulating layer, a magnetic layer, and external electrodes, where the magnetic layer is strategically positioned to enhance magnetic permeability and saturation magnetization without altering the body material, allowing for improved inductance and reduced coil turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of coil turns is reduced to decrease component size, then the volume is reduced, but the inductance properties deteriorate
Solution Approach 1:
The patent applies composite materials by combining a magnetic layer with high magnetic permeability and high saturation magnetization value with the coil structure. This magnetic layer is formed on the surface of the coil winding, creating a composite structure that enhances inductance properties without requiring an increased number of turns, thereby maintaining compact size while improving inductance performance.
2Reliability
If high magnetic permeability material is used to improve inductance within reduced size, then the inductance properties are improved, but the saturation magnetization value is limited by material constraints
Solution Approach 1:
The patent overcomes material limitations by forming a magnetic layer with superior magnetic properties on the coil surface. This layer acts as a magnetic shield and enhances the overall magnetic performance, allowing the component to achieve both high magnetic permeability and high saturation magnetization value that cannot be obtained with conventional bulk materials alone.
3Volume of moving object
If the coil size is reduced to fit compact devices, then the component volume decreases, but the Rdc properties deteriorate
Solution Approach 1:
The magnetic layer forms a protective composite structure around the coil that shields the winding from external magnetic fields and physical damage. This composite structure allows for reduced component volume while maintaining or even improving Rdc properties through enhanced magnetic field confinement and reduced eddy current losses.
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 design effectively increases inductance and saturation magnetization values, reduces the number of coil turns, and enhances Rdc properties, enabling high-performance coil components in reduced sizes.
Implementation Method 1
a magnetic layer disposed on the first insulating layer, covering at least a portion of the first insulating layer and spaced apart from the surface of the body
Implementation Method 2
improved Isat properties by increasing a saturation magnetization value through a magnetic layer
Data Source
AI summary
A coil component includes a body, a coil disposed within the body, a first insulating layer covering at least a portion of the coil, an external electrode disposed on one surface of the body and connected to the coil at the one surface of the body, and a magnetic layer disposed on the first insulating layer, covering at least a portion of the first insulating layer and spaced apart from the surface of the body, and in which an the external electrode is disposed on the body, connected to the coil, and spaced apart from the magnetic layer. Additionally, the coil component can include a second insulating layer covering at least a portion of the magnetic layer.