Multilayer Coil Component with Graded Soft Magnetic Powder
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Solution Overview
Problem
Multilayer coil components with small soft magnetic metal powder particle diameters have low permeability, leading to increased coil resistance and difficulty in reducing losses at high frequencies, as higher winding numbers are required to increase inductance, which in turn increase resistance.
Innovation Solution
The multilayer coil component design features soft magnetic metal powders with larger average particle diameters at the inner and outer sides of the coil, while using smaller diameters between internal conductors, enhancing permeability and reducing high-frequency losses by forming an effective magnetic path around the conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the permeability of the element body is increased by using small particle diameter soft magnetic metal powders, then the inductance value increases, but the resistance component of the coil increases at high frequencies
Solution Approach 1:
The patent applies local quality by using soft magnetic metal powders with different average particle diameters in different regions of the element body. Specifically, the first soft magnetic metal powders with a first average particle diameter are used in a first region, while the second soft magnetic metal powders with a second average particle diameter (smaller than the first) are used in a second region. This spatial variation in material properties allows different regions to fulfill different functional requirements, resolving the contradiction between achieving high inductance and minimizing high-frequency resistance.
2Reliability
If the number of winding of the coil is increased to increase inductance, then the inductance value increases, but the resistance component of the coil increases
Solution Approach 1:
The patent changes the physical parameter of the soft magnetic metal powders (average particle diameter) to achieve the desired inductance value. By using powders with smaller average particle diameter in the second region, the permeability is enhanced, which increases the inductance without requiring an increased number of windings. This parameter change approach allows achieving high inductance while maintaining lower coil resistance and simpler structure.
3Reliability
If the permeability of the element body is increased, then the inductance increases, but it becomes difficult to reduce loss at the high frequency side
Solution Approach 1:
The patent resolves this contradiction by applying local quality through regional differentiation of soft magnetic metal powder characteristics. The first region uses powders with larger average particle diameter for baseline permeability, while the second region uses powders with smaller average particle diameter to provide enhanced permeability where needed. This localized optimization allows the element body to achieve high overall permeability for increased inductance while specific regions are optimized to minimize high-frequency losses.
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 design achieves higher permeability and reduced losses at high frequencies by strategically varying the particle diameters of soft magnetic metal powders within the coil, effectively managing resistance and inductance.
Implementation Method 1
At the high frequency side, a magnetic path is formed around the internal conductors, so that the action between the internal conductors adjacent to each other in the first direction is effectively provided.
Implementation Method 2
an element body that includes soft magnetic metal powders
Data Source
AI summary
A multilayer coil component includes an element body including soft magnetic metal powders and a coil disposed in the element body. The coil includes a plurality of internal conductors electrically connected to each other. The plurality of internal conductors are separated from each other in a first direction and are adjacent to each other in the first direction. An average particle diameter of the soft magnetic metal powders located at an inner side of the coil when viewing from the first direction is larger than an average particle diameter of the soft magnetic metal powders located between the internal conductors adjacent to each other in the first direction.