Multilayer Coil Structure With Resistive Layers Against Short Circuits
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Solution Overview
Problem
Multilayer coil components face issues with short circuits between adjacent coil conductors due to insufficient insulation resistance, which can lead to electrical failures and reliability concerns.
Innovation Solution
Incorporating a first and second resistive layer between adjacent coil conductors, with the resistive layers in contact with the coil conductors and having a wider width than the conductors, along with a stress relaxation layer to manage internal stress and prevent cracking, thereby enhancing insulation resistance and reducing short circuit occurrences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil conductors are arranged adjacently to increase density, then productivity and compactness improve, but insulation resistance decreases leading to short circuits
Solution Approach 1:
A resistive layer is introduced as an intermediary substance between adjacent coil conductors. This resistive layer serves as a mediator that provides electrical insulation while allowing the conductors to remain in close proximity, thus maintaining high coil density while preventing short circuits through improved insulation resistance.
Solution Approach 2:
The insulation structure is extended from a simple planar arrangement to a three-dimensional configuration by adding the resistive layer in the vertical dimension between conductors. This dimensional approach allows conductors to be densely packed in the horizontal plane while maintaining adequate insulation through the vertical resistive layer.
2Reliability
If resistive layer width is increased to improve insulation, then insulation resistance improves, but device complexity increases
Solution Approach 1:
The resistive layer is designed to serve multiple functions simultaneously: it provides electrical insulation between conductors, acts as a structural support layer, and serves as a base for subsequent resistive patterns. This multi-functionality reduces the need for additional separate layers, thereby limiting the increase in device complexity while maintaining improved insulation resistance.
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 solution effectively increases insulation resistance between coil conductors, significantly reducing the occurrence of short circuits and ensuring reliable operation by using resistive layers made of zirconia and a stress relaxation layer to manage internal stress and prevent cracking.
Implementation Method 1
The stress relaxation layer relaxes internal stress in the element body. A configuration including the stress relaxation layer reduces occurrence of a crack between the first coil conductor and the second coil conductor.
Data Source
AI summary
A multilayer coil component includes an element body, a plurality of coil conductors, a first resistive layer, and a second resistive layer. The plurality of coil conductors are disposed in the element body and electrically connected to each other. The plurality of coil conductors include a first coil conductor and a second coil conductor adjacent to each other. The first resistive layer and the second resistive layer oppose each other between the first coil conductor and the second coil conductor. The first resistive layer is in contact with the first coil conductor.