Multilayer Coil Protrusions Reduce DC Resistance
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Solution Overview
Problem
Multilayer inductors face increased direct-current resistance due to higher inductance, which can be exacerbated by widening coil patterns, leading to reduced inductance values and deterioration of direct-current superimposition characteristics, and are prone to short circuits during production.
Innovation Solution
The multilayer coil device features a multilayer body with alternately stacked insulating layers and spiral coil patterns, including protrusions in specific regions to maintain line width and prevent short circuits, reducing direct-current resistance while maintaining inductance and superimposition performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the line width of coil patterns is increased to reduce direct-current resistance, then direct-current resistance decreases, but inductance value reduces and direct-current superimposition characteristics deteriorate
Solution Approach 1:
The invention applies different line widths to different regions of the coil pattern. Specifically, the first coil pattern has a first line width while the second coil pattern has a second line width that is different from the first. This local differentiation allows optimization of current distribution and magnetic field generation, reducing direct-current resistance without compromising overall inductance and superimposition characteristics.
2Loss of energy
If the line width of coil patterns is increased to reduce direct-current resistance, then direct-current resistance decreases, but the inside diameter area and side gap width reduce
Solution Approach 1:
By assigning different line widths to different coil patterns (first vs. second line width), the invention optimizes the balance between conductor area and magnetic core geometry. This allows sufficient current-carrying capacity to reduce resistance while preserving adequate inside diameter area and side gap width for magnetic flux distribution.
3Productivity
If sheet lamination technique is used for production, then manufacturing efficiency improves, but coil patterns may be deformed by smearing or pressure causing short circuits
Solution Approach 1:
The invention designs the coil pattern with specific geometric features (different line widths in different regions) that preemptively compensate for potential deformation during sheet lamination. The varied line width design ensures that even if some smearing or pressure-induced deformation occurs during manufacturing, the critical electrical and magnetic performance characteristics are maintained, preventing short circuits.
Data Source
AI summary
A multilayer coil device is formed by alternately stacking a plurality of insulating layers and a plurality of substantially spiral coil patterns. In the multilayer coil device, the number of turns of each of the substantially spiral coil patterns is more than one. Each of the substantially spiral coil patterns has a protrusion protruding toward a center of the substantially spiral coil pattern. The protrusion is located in a specific region where the number of coil pattern portions that cross a virtual line extending radially outward from the center of the coil pattern is smaller than that in another region of the substantially spiral coil pattern. The protrusion is provided as an additional part of a coil pattern portion that is closest to the center of the substantially spiral coil pattern in the specific region.