Multilayer Coil Component Using Fine Magnetic Particles for DC Bias
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Solution Overview
Problem
Existing thin film inductors face challenges in achieving high DC bias effects and magnetic flux saturation due to limitations in particle size distribution of magnetic particles, which restricts sheet thickness and inductance performance.
Innovation Solution
A coil electronic component with a multilayer structure incorporating magnetic particles with a particle size distribution of 3.5 μm or less, allowing for a core and cover portion with different thicknesses and particle sizes to enhance DC-Bias characteristics and lamination design freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles having a large particle size are used to secure a magnetic saturation region, then magnetic saturation magnetization (Ms) is improved, but sheet thickness cannot be formed to be thick and DC bias effect deteriorates
Solution Approach 1:
The patent changes the particle size parameter from large particles to small particles (D50 of 3.5 μm or less) to resolve the contradiction. This parameter change enables both adequate sheet thickness and improved DC bias characteristics while maintaining magnetic saturation magnetization through optimized particle distribution in the multilayer structure.
Solution Approach 2:
The patent segments the inductor body into multiple layers with different particle size distributions. The core portion contains finer particles (D50 ≤ 3.5 μm) for high DC bias effect, while the cover portion may contain coarser particles for magnetic saturation. This segmentation allows each layer to optimize its function independently, resolving the thickness vs. saturation magnetization contradiction.
2Reliability
If particles having a small particle size are used to improve DC bias effect, then DC bias characteristics are improved, but sheet thickness is limited and magnetic saturation region deteriorates
Solution Approach 1:
The patent optimizes the particle size parameter to D50 of 3.5 μm or less, which is small enough to enable thick sheet formation and high DC bias characteristics while maintaining adequate magnetic saturation magnetization through the optimized particle size distribution in the multilayer configuration.
Solution Approach 2:
The patent transitions from a single-layer structure to a multilayer structure, adding the dimensional aspect of layering. This allows the system to achieve both thin sheet thickness and high magnetic saturation magnetization by stacking multiple layers with optimized particle sizes, effectively resolving the contradiction through dimensional expansion.
3Ease of manufacture
If a single layer structure is used, then manufacturing is simple, but DC bias characteristics and lamination design freedom deteriorate
Solution Approach 1:
The patent segments the single layer structure into multiple layers (core portion and cover portion) with different particle size characteristics. This segmentation enables optimization of DC bias characteristics in the core portion while maintaining manufacturing feasibility through standardized lamination processes, resolving the contradiction between manufacturing simplicity and performance.
Solution Approach 2:
The patent applies local quality by giving different particle size distributions to different portions of the inductor body. The core portion uses fine particles (D50 ≤ 3.5 μm) for high DC bias effect, while the cover portion may use coarser particles. This local differentiation achieves superior DC bias characteristics without significantly complicating the overall manufacturing process.
4Device complexity
If a single layer structure is used, then device complexity is low, but lamination design freedom deteriorates
Solution Approach 1:
The patent segments the structure into modular layers (core portion and cover portion) that can be independently designed and assembled. This segmentation provides lamination design freedom by allowing different particle size distributions, thicknesses, and material compositions in each layer, while maintaining relatively low overall device complexity through standardized manufacturing processes.
Solution Approach 2:
The patent creates a universal multilayer structure that can accommodate different particle size distributions and thickness configurations to meet various performance requirements. This universal design approach enhances lamination design freedom, allowing the same basic structure to be adapted for different applications by simply adjusting layer parameters without redesigning the entire device.
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 solution enables improved DC-Bias characteristics and increased flexibility in lamination design, enhancing inductance performance and reducing surface roughness while maintaining high magnetic permeability and saturation magnetization.
Implementation Method 1
to secure a magnetic saturation region
Implementation Method 2
maintaining high magnetic permeability and saturation magnetization
Implementation Method 3
Inductors, coil electronic components, are representative passive elements forming electronic circuits
Data Source
AI summary
A coil electronic component includes a body including magnetic particles and an insulating resin, and a coil portion disposed within the body. The body has a multilayer structure including a core portion covering the coil portion and a cover portion covering the core portion. The magnetic particles included in the core portion have a distribution of a particle size having a D50 of 3.5 μm or less.