Multilayer Coil Recesses for Inductance
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Solution Overview
Problem
Conventional multilayer electronic components with helical coils face challenges in achieving a high inductance value due to eddy current losses caused by varying magnetic flux directions, which result in reduced inductance values.
Innovation Solution
The electronic component features a laminate with insulator layers and helically wound coil conductor layers that have recesses on their surfaces directed towards the inner circumference, reducing eddy currents by shortening the distance magnetic flux travels through the coil conductor layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the coil conductor patterns are made wider or thicker to achieve low direct-current resistance, then the direct-current resistance decreases, but the manufacturing complexity increases
Solution Approach 1:
The coil conductor patterns are segmented into functionally distinct regions: inner circumference side portions with recesses for reducing eddy currents, and outer circumference side portions with sufficient dimensions for low DC resistance. This segmentation allows each region to be optimized independently for its specific purpose while maintaining overall manufacturability through standardized formation processes.
2Loss of energy
If the recesses are made deeper to further reduce eddy currents, then the inductance value increases, but the manufacturing precision requirements increase
Solution Approach 1:
The invention optimizes the recess depth parameter within a specific range (6 μm or more, preferably 10 μm or more, and 40% or less of the coil conductor layer width) to achieve effective eddy current reduction while maintaining manufacturability. This parameter optimization balances the competing requirements of maximizing inductance value and ensuring manufacturing precision, identifying a sweet spot where sufficient eddy current suppression is achieved without excessive manufacturing difficulty.
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 effectively increases the inductance value of the coil by minimizing eddy current losses, as demonstrated by computer simulations, while maintaining a depth of recesses within optimal parameters.
Implementation Method 1
eddy currents are generated in the coil conductor patterns, so that Joule's heat is produced
Implementation Method 2
the density of magnetic flux in the coil is high. In this case, magnetic flux that does not flow through the coil passes through the surfaces of the coil conductor patterns
Data Source
AI summary
An electronic component having: a laminate formed by laminating a plurality of insulator layers; and a coil consisting of linear coil conductor layers that are laminated along with the insulator layers, the coil having a spiral form or a helical form that windingly extends in a direction of lamination. In a cross section perpendicular to a direction in which the coil conductor layers extend, the coil conductor layers have recesses provided in their surfaces directed toward an inner circumference side of the coil, the recesses being set back toward an outer circumference side of the coil.