Multilayer Coil Component With Insulating Grains
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Solution Overview
Problem
Existing multilayer coil components face challenges in increasing current capacities while preventing shorting and maintaining high inductance, particularly when using metal magnetic materials instead of ferrite materials.
Innovation Solution
A multilayer coil component design featuring a substrate body with magnetic layers containing metal magnetic grains and high-hardness insulating grains, where the insulating grains are harder and smaller than the metal magnetic grains, are placed between conductor and magnetic layers to enhance fill ratio and winding density, thereby increasing inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If metal magnetic materials are used instead of ferrite materials to increase current capacity, then inductance is improved, but shorting between conductor layers occurs due to lower insulating properties
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the conductor layers to provide electrical insulation. The resin layer has higher insulating properties than the metal magnetic material, preventing shorting while allowing the metal magnetic material to provide high inductance and current capacity
Solution Approach 2:
The coil component uses a composite structure combining metal magnetic material layers with resin layers. The metal magnetic material provides magnetic properties and current capacity, while the resin provides insulating properties, creating a composite material system that achieves both high inductance and electrical insulation
2Power
If the spacing between conductor layers is reduced to increase winding density, then inductance is improved, but the risk of shorting increases
Solution Approach 1:
The resin layer serves as a mediator that enables reduced spacing between conductor layers while maintaining insulation. It fills the gap between conductors, allowing tighter winding density for higher inductance without compromising electrical isolation
Solution Approach 2:
The resin layer changes the electrical parameter (insulating property) of the spacing region, allowing the geometric parameter (spacing distance) to be reduced while maintaining the electrical property (insulation) necessary to prevent shorting
3Length of stationary object
If the height of the coil component is reduced, then miniaturization is achieved, but the fill ratio of metal magnetic grains and winding density decrease
Solution Approach 1:
The design shifts optimization from the vertical dimension (height) to the lateral dimension (planar area). By improving the fill ratio of metal magnetic grains in the planar direction and optimizing the winding layout, inductance is maintained or improved while reducing overall height for miniaturization
Data Source
AI summary
In an exemplary embodiment, a multilayer coil component includes: a substrate body; and a coil embedded in the substrate body and containing a wound conductor; wherein the substrate body has: magnetic layers containing multiple metal magnetic grains, provided around conductor layers that constitute parts of the wound conductor in a direction roughly orthogonal to the coil axis of the coil; and multiple high-hardness insulating grains harder than the multiple metal magnetic grains and smaller in average grain size than the multiple metal magnetic grains, provided between a pair of the conductor layers adjacent to each other in the direction of the coil axis and also between a pair of the magnetic layers adjacent to each other in the direction of the coil axis. The multilayer coil component can prevent shorting in the wound conductor while increasing the inductance.