Multilayer Coil Structure With Dissimilar Surface Layers
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Solution Overview
Problem
Existing multilayer coil components made with glass-based insulating layers have limitations in inductance and strength characteristics.
Innovation Solution
Incorporating a dissimilar-material layer made of a material different from the insulating layers on the outer surfaces of the multilayer coil component, such as a ferrite material or crystallized glass, to enhance inductance and strength, and using a photolithography method for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass-based insulating layers are used in multilayer coil components, then manufacturing ease and basic insulation are improved, but inductance and strength characteristics deteriorate
Solution Approach 1:
The patent applies composite materials by combining glass-based insulating layers with ferrite-based dissimilar-material layers. The glass layers provide ease of manufacture and insulation, while the ferrite layers enhance strength and inductance characteristics. This composite structure resolves the contradiction by allowing each material to contribute its advantageous properties.
Solution Approach 2:
The patent applies local quality by placing dissimilar-material layers specifically on outer surfaces that extend in the lamination direction, rather than uniformly throughout the entire component. This localized application enhances strength where needed while maintaining manufacturing efficiency in other areas.
2Ease of manufacture
If glass-based insulating layers are used in multilayer coil components, then manufacturing ease and basic insulation are improved, but inductance characteristics deteriorate
Solution Approach 1:
The combination of glass-based insulating layers with ferrite-based dissimilar-material layers creates a composite structure where the ferrite material provides enhanced inductance characteristics while the glass material maintains ease of manufacture and insulation properties.
Solution Approach 2:
By applying dissimilar-material layers specifically on outer surfaces extending in the lamination direction, the patent locally enhances inductance characteristics where the magnetic field is most relevant, while maintaining manufacturing efficiency elsewhere.
3Strength
If dissimilar-material layers are added to enhance inductance and strength, then performance characteristics are improved, but device complexity increases
Solution Approach 1:
The dissimilar-material layers are applied only on outer surfaces that extend in the lamination direction, not throughout the entire component. This localized approach enhances flexural strength where it is most needed while minimizing the increase in structural complexity.
Solution Approach 2:
The dissimilar-material layers serve multiple functions simultaneously: they enhance inductance characteristics, improve flexural strength, and provide structural support. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
Data Source
AI summary
A multilayer coil component includes an element body that includes a plurality of insulating layers laminated together, a coil that is embedded in the element body and that includes a coil conductor layer provided between the insulating layers, and a first outer electrode and a second outer electrode each of which is provided on at least one of outer surfaces of the element body and each of which is electrically connected to the coil. A dissimilar-material layer that is made of a material different from the insulating layers is provided on at least one of the outer surfaces of the element body that extend in a lamination direction in which the plurality of insulating layers are laminated together.