Multilayer Coil Conductor Geometry for High-Current Inductance
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Solution Overview
Problem
Existing multilayer coil components face challenges in increasing the sectional area of coil conductors to accommodate large electric current while maintaining efficient inductance, as enlarging the conductor size reduces the inner diameter and affects efficiency.
Innovation Solution
A multilayer coil component design with a specific thickness-to-width ratio of 1.5 to 4.0 for coil conductors, allowing increased sectional area without reducing the inner diameter, achieved through a printing lamination method that forms coil conductors without tapering, enabling large electric current flow and high inductance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sectional area of the coil conductor is increased by increasing the size of the coil conductor, then the amount of electric current flowing through the multilayer coil component is increased, but the inner diameter of the coil is reduced
Solution Approach 1:
The patent changes the dimensional approach by controlling the thickness-to-width ratio of coil conductors within 1.5 to 4.0, optimizing the distribution of conductor material across different dimensions. This allows increasing the sectional area (particularly through thickness) without proportionally increasing width, thereby maintaining the inner diameter while accommodating larger current requirements.
Solution Approach 2:
The patent applies parameter changes by establishing a specific range for the thickness-to-width ratio (1.5 to 4.0) of coil conductors. This parameter optimization enables the conductor cross-section to be enlarged for higher current capacity while the aspect ratio control ensures the coil's inner diameter is preserved, resolving the contradiction between current capacity and inductance efficiency.
2Quantity of substance
If the inner diameter of the coil is reduced to increase the sectional area of the coil conductor, then the amount of electric current flowing through the multilayer coil component is increased, but the efficiency in obtaining inductance is reduced
Solution Approach 1:
The patent optimizes the thickness-to-width ratio parameter within 1.5 to 4.0 to achieve the desired balance. This parameter control allows the conductor sectional area to be increased for higher current capacity while maintaining the coil's geometric efficiency for inductance generation, thus avoiding the energy loss associated with reduced inductance efficiency.
Solution Approach 2:
The patent utilizes dimensional optimization by focusing on increasing conductor thickness rather than width, allowing the sectional area to grow without compromising the coil's inner diameter. This dimensional strategy preserves the magnetic field generation efficiency while accommodating higher current requirements.
3Quantity of substance
If the size of the coil conductor is increased to accommodate large electric current, then the electric current capacity is increased, but the number of turns required is reduced
Solution Approach 1:
The patent controls the thickness-to-width ratio within 1.5 to 4.0, which allows each conductor to carry more current with optimized dimensions. This parameter optimization means fewer turns are needed to achieve the same total current capacity and inductance, improving manufacturing productivity by reducing the number of lamination steps and conductor pieces required.
Data Source
AI summary
A multilayer coil component includes a multilayer body including a plurality of insulating layers and a coil therein; and first and second outer electrodes electrically connected to the coil. An axial direction of the coil is parallel to a mounting surface of the multilayer coil component. A laminating direction of the multilayer body is perpendicular to the mounting surface. When in a section of a coil conductor extending in the laminating direction, the section being taken along a plane parallel to the mounting surface, a dimension of the coil conductor in a direction parallel to an axis of the coil is a thickness of the coil, and a dimension of the coil conductor in a direction orthogonal to a direction of the thickness of the coil is a width of the coil, a value of the thickness of the coil/the width of the coil is from 1.5 to 4.0.