Multilayer Coil Component Layout for Higher Self-Resonance
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Solution Overview
Problem
Existing coil components with a helical coil pattern embedded in a resin body face challenges in achieving a sufficient self-resonance frequency due to high floating capacitance and mechanical strength limitations.
Innovation Solution
The coil component incorporates a resin body with layers of different resin-based insulating materials, where high-strength layers with added filler are combined with low-permittivity layers without filler, and terminal electrodes are arranged parallel to the coil axis to reduce floating capacitance and ensure mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single resin-based insulating material is used in the resin body, then the manufacturing process is simple, but the self-resonance frequency cannot be sufficiently increased due to high floating capacitance
Solution Approach 1:
The resin body is segmented into multiple resin layers (first resin layer, second resin layer, third resin layer) with different insulating materials. The first and third resin layers use high-strength resin-based insulating material, while the second resin layer uses low-permittivity resin-based insulating material. This segmentation allows simultaneous achievement of mechanical strength and reduced floating capacitance for increased self-resonance frequency.
Solution Approach 2:
Different regions of the resin body are assigned different insulating materials based on their specific functional requirements. The second resin layer, which directly contacts the coil pattern, uses low-permittivity material to reduce floating capacitance, while the first and third resin layers use high-strength material for mechanical support. This local differentiation optimizes both electrical performance and structural integrity.
2Strength
If high-strength resin-based insulating material is used throughout the resin body, then mechanical strength is ensured, but floating capacitance increases and self-resonance frequency decreases
Solution Approach 1:
The patent applies different resin-based insulating materials to different resin layers based on local functional requirements. The second resin layer uses low-permittivity material to reduce floating capacitance where it directly contacts the coil pattern, while the first and third resin layers use high-strength material for mechanical support. This local differentiation allows simultaneous optimization of both mechanical strength and electrical performance.
Solution Approach 2:
The resin body is constructed as a composite structure with multiple resin layers made of different resin-based insulating materials. This composite approach combines the advantages of high-strength material (mechanical support) and low-permittivity material (reduced floating capacitance) to achieve both mechanical strength and increased self-resonance frequency.
3Device complexity
If the coil pattern is embedded in a single-layer resin structure, then the structure is simple, but floating capacitance between terminal electrodes and coil pattern cannot be reduced
Solution Approach 1:
The resin body is segmented into multiple resin layers with different insulating materials. The second resin layer, positioned between the terminal electrodes and the coil pattern, uses low-permittivity material to reduce floating capacitance. This segmentation into functional layers reduces floating capacitance while maintaining a relatively simple overall structure.
4Strength
If filler is added to the resin-based insulating material, then mechanical strength increases, but relative permittivity increases and floating capacitance increases
Solution Approach 1:
The patent applies different resin-based insulating materials to different resin layers based on local functional requirements. The second resin layer, which directly contacts the coil pattern and terminal electrodes, uses low-permittivity material to reduce floating capacitance, while the first and third resin layers use high-strength material with filler for mechanical support. This local differentiation allows simultaneous optimization of both mechanical strength and electrical performance.
Solution Approach 2:
The resin body is constructed as a composite structure with multiple resin layers made of different resin-based insulating materials. This composite approach combines the advantages of high-strength material (mechanical support) and low-permittivity material (reduced floating capacitance) to achieve both mechanical strength and increased self-resonance frequency.
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 configuration enhances mechanical strength and reduces floating capacitance, thereby increasing the self-resonance frequency and improving mounting density while suppressing eddy currents.
Implementation Method 1
a resin body having a first resin-based insulating material and a second resin-based insulating material lower in relative permittivity than the first resin-based insulating material
Implementation Method 2
This makes magnetic flux less likely to interface with the first and second terminal electrodes, thereby suppressing the occurrence of an eddy current
Data Source
AI summary
Disclosed herein is a coil component that includes a resin body having a first resin-based insulating material and a second resin-based insulating material lower in relative permittivity than the first resin-based insulating material, a coil pattern embedded in the resin body and helically wound in a plurality of turns, and first and second terminal electrodes formed on a surface of the resin body and connected respectively to one and other ends of the coil pattern. The coil pattern has a part covered with the first resin-based insulating material and another part covered with the second resin-based insulating material.