Multilayer Coil Component Non-Magnetic Layer Design
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Solution Overview
Problem
Multilayer coil components of open magnetic path type experience magnetic saturation due to magnetic flux circling around individual coil conductors, which affects their direct-current superposition characteristics.
Innovation Solution
A manufacturing method for an electronic component that forms a laminate with a helical coil using insulator layers with varying nickel and bismuth content rates, where non-magnetic layers are created between coil conductors to prevent excessive magnetic flux density and reduce magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayer coil component uses a laminate with uniform magnetic properties, then the magnetic flux distribution is concentrated, but magnetic saturation occurs due to excessive magnetic flux density around individual coil conductors
Solution Approach 1:
The laminate is designed with non-magnetic layers (having different magnetic properties from magnetic layers) positioned between adjacent coil conductors. This creates local variations in magnetic permeability, causing magnetic flux to preferentially pass through the non-magnetic layers rather than concentrating around individual coil conductors, thereby suppressing magnetic saturation and improving direct-current superposition characteristics.
2Reliability
If non-magnetic layers are added between coil conductors, then magnetic saturation is suppressed, but the laminate structure becomes more complex
Solution Approach 1:
The laminate is segmented into alternating magnetic layers and non-magnetic layers. The non-magnetic layers are positioned between adjacent coil conductors in the lamination direction, creating a segmented structure that guides magnetic flux distribution. This segmentation approach suppresses magnetic saturation while maintaining a systematic and manufacturable laminate structure.
Solution Approach 2:
The laminate is constructed as a composite structure combining magnetic layers (with high magnetic permeability) and non-magnetic layers (with different magnetic properties). This composite material approach allows the laminate to exhibit optimized magnetic flux distribution characteristics, suppressing magnetic saturation around coil conductors while maintaining structural integrity.
3Ease of manufacture
If the laminate structure is simplified, then manufacturing is easier, but magnetic flux concentration causes magnetic saturation
Solution Approach 1:
The laminate is segmented into alternating magnetic layers and non-magnetic layers, where non-magnetic layers are positioned between adjacent coil conductors. This segmentation creates natural flux paths through the non-magnetic layers, preventing magnetic flux concentration around individual conductors. The segmented structure can be manufactured using conventional lamination techniques, balancing manufacturing ease with 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
The method effectively suppresses magnetic saturation and improves direct current superposition characteristics by ensuring magnetic flux passes through non-magnetic layers, maintaining inductance and reducing the occurrence of magnetic saturation.
Implementation Method 1
a magnetic flux φ510 circling around the coil L passes through the non-magnetic layer 504
Data Source
AI summary
An electronic component and manufacturing method for preparing an electronic component includes providing a first insulator layer having a first nickel content rate. A coil conductor and a second insulator layer having a first bismuth content rate and a second nickel content rate higher than the first nickel content rate are provided on the first insulator layer. The first insulator layer, the coil conductor, and the second insulator layer constitute a first unit layer. The first unit layer and an exterior insulator layer are laminated to obtain a laminate. After a step of firing the laminate, a nickel content rate in a first portion of the first insulator layer, the first portion being sandwiched between the coil conductors from both sides facing in a lamination direction, is lower than a nickel content rate in a second portion of the first insulator layer other than the first portion.