Multilayer Coil Structure With Boundary Void for Low DC Resistance
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Solution Overview
Problem
In multilayer coil components, stress between the insulating portion and the coil leads to variations in electrical characteristics, and existing stress-alleviating methods increase DC resistance due to reduced cross-sectional area of the coil conductor.
Innovation Solution
A multilayer coil component design featuring a groove-shaped void portion at the boundary between the coil and the insulator with a ridge extending in the coil length direction, which increases the cross-sectional area and reduces DC resistance while alleviating internal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a stress-alleviating space containing powder is disposed across the entire lower surface of the coil conductor, then stress between the insulator portion and coil is alleviated, but the cross-sectional area of the coil conductor is decreased and DC resistance is increased
Solution Approach 1:
The invention applies the local quality principle by positioning the void portion specifically at the boundary between the coil and insulator portion rather than across the entire lower surface. This localized approach provides stress relief precisely where the stress concentration occurs at the interface, while preserving the cross-sectional area of the coil conductor in the central current-carrying region, thus maintaining low DC resistance.
Solution Approach 2:
The invention segments the stress-alleviating function by creating a discrete void portion with specific dimensions (width of 80% or less of the coil conductor width) rather than using a continuous stress-alleviating space. The ridge structure within the void portion further segments the space, providing targeted stress relief while minimizing impact on the overall conductor cross-section.
2Stress or pressure
If the cross-sectional area of the coil conductor is decreased to create space for stress relief, then stress is alleviated, but DC resistance increases
Solution Approach 1:
The invention resolves the contradiction by transitioning from a two-dimensional approach (reducing cross-sectional area) to a three-dimensional approach (creating a void portion with specific width and depth at the boundary). The void portion extends in the length direction of the coil and has controlled dimensions, providing stress relief through vertical and lateral spacing rather than by reducing the conductor's current-carrying cross-section.
Solution Approach 2:
The void portion is strategically positioned at the boundary region where stress concentration occurs, applying the local quality principle. The width of the void portion is controlled to be 80% or less of the coil conductor width, ensuring that stress relief is provided locally at the interface without significantly impacting the overall cross-sectional area available for current flow.
Data Source
AI summary
A coil component in which stress inside thereof is alleviated and the DC resistance is low. A multilayer coil component includes an element body that includes an insulator portion and a coil embedded in the insulator portion; and outer electrodes disposed on surfaces of the insulator portion and electrically connected to ends of the coil. There is a groove-shaped void portion at a boundary between the coil and the insulator portion, and the void portion extends in a length direction of the coil. The coil has a ridge in the void portion, and the ridge extends in the length direction of the coil.