Multilayer Coil Structure for High Inductance in Thin Magnetic Layers
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Solution Overview
Problem
The challenge is to enhance the inductance of coil components while maintaining a compact size, as reducing the thickness of magnetic layers to increase winding density leads to lower magnetic permeability, making it difficult to achieve high inductance even with increased winding density.
Innovation Solution
The coil component design includes alternately stacked oblate soft magnetic grain-containing layers and spherical grain-containing layers, with the oblate layers being thinner and the spherical layers filling gaps to maintain permeability, and cover parts with spherical grains to suppress magnetic flux leakage, allowing for reduced thickness and increased winding density without compromising inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of magnetic layers is reduced to increase winding density, then the winding density of the coil is improved, but the magnetic permeability of the magnetic layers deteriorates
Solution Approach 1:
The patent applies local quality by using oblate soft magnetic grains with specific orientation in the magnetic layers. The oblate grains are arranged such that their thickness direction (short axis) is oriented in the stacking direction of the magnetic layers, creating anisotropic magnetic properties that maintain high permeability even in thin layers. This localized structural optimization allows thin magnetic layers to achieve both high winding density and maintained magnetic permeability.
Solution Approach 2:
The patent changes the physical parameters of the magnetic grains by using oblate (flattened) shapes with aspect ratios of 2:1 or greater. This parameter change in grain morphology, combined with specific orientation during lamination, enables the magnetic layers to maintain high permeability at reduced thicknesses, thereby resolving the contradiction between thin layer requirements for high winding density and the need for sufficient magnetic permeability.
2Length of stationary object
If the sizes of soft magnetic grains are reduced to make magnetic layers thinner, then the thickness of magnetic layers is reduced, but the magnetic permeability of the magnetic layers deteriorates
Solution Approach 1:
The patent uses oblate soft magnetic grains with their short axis oriented in the stacking direction, creating directional magnetic properties. This local structural quality ensures that magnetic flux preferentially travels through the plane of the oblate grains rather than across their thickness, maintaining high permeability even when layer thickness is reduced to accommodate smaller grains and achieve higher winding densities.
Solution Approach 2:
The patent employs a composite structure combining oblate soft magnetic grains with insulating materials in the inter-grain spaces. This composite approach allows the use of smaller grains while maintaining overall magnetic permeability through the oriented oblate grain structure, and the insulating material prevents eddy current losses that would otherwise increase with reduced grain size and thinner layers.
3Quantity of substance
If the pitch of the coil is shortened to increase winding density, then the winding density of the coil is improved, but the magnetic layers must be made thinner which reduces magnetic permeability
Solution Approach 1:
The patent applies local quality optimization by orienting oblate soft magnetic grains with their short axes perpendicular to the coil windings. This creates regions of high magnetic permeability aligned with the magnetic flux paths generated by the densely wound coil, allowing the system to achieve high inductance despite the reduced pitch and thinner magnetic layers required for high winding density.
Solution Approach 2:
The patent changes the morphological parameters of the magnetic grains to oblate shapes with controlled aspect ratios, and optimizes their orientation during lamination. This parameter optimization enables the magnetic layers to maintain sufficient permeability even when made thinner to accommodate the shortened coil pitch, thereby allowing high winding density to be achieved without sacrificing magnetic performance.
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 configuration improves the magnetic permeability and inductance of the coil component by allowing thinner magnetic layers and higher winding density, while effectively blocking magnetic flux leakage and ensuring insulation, thus achieving high inductance in a compact form.
Implementation Method 1
the magnetic permeability of the magnetic layers becomes lower... the oblate soft magnetic grain-containing layers formed by the oblate soft magnetic grains are provided in the magnetic body part... the inductance of the coil component can be improved because the oblate soft magnetic grain-containing layers formed by the oblate soft magnetic grains are provided in the magnetic body part
Implementation Method 2
soft magnetic alloys have conductivity, so the coil components described in Patent Literatures 1 to 3 require constitutions that ensure insulation property of the magnetic body part... formed by insulative spherical grains
Implementation Method 3
cover parts covering the first and second magnetic layers from the one axis direction... effectively blocking magnetic flux leakage
Data Source
AI summary
A coil component includes: a magnetic body part and a cover part covering one side of a magnetic layer part; and a coil part embedded in the magnetic body part. The magnetic body part is comprised of the following two types of layers: (A) an oblate soft magnetic grain-containing layer, and (B) a spherical grain-containing layer, wherein layer (A) extends over the entire range of the magnetic body part except for a portion including the coil part in a direction perpendicular to an axis direction of the coil part, layer (B) adjoins layer (A) in the axis direction. The cover part is constituted by multiple layers including one or more of layer(s) (A) and one or more of layer(s) (B) and extending over the entire range of the magnetic body part in the direction perpendicular to the axis direction.