Multilayer Common Mode Filter with Segmented Magnetic Layers
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Solution Overview
Problem
Conventional multilayer common mode filters face issues with crack formation due to stress from differential shrinkage between nonmagnetic and magnetic layers, and difficulty in controlling the volume of magnetic layers, which affects magnetic coupling and reliability.
Innovation Solution
A multilayer common mode filter design where magnetic layers are placed within the inner region of spiral coil conductors, with nonmagnetic layers arranged alternately to reduce shrinkage differences and prevent cracks, while maintaining effective magnetic coupling by controlling the volume of magnetic layers through surface disposition and thickness equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a magnetic layer penetrates through the center part of the coil conductors to enhance magnetic coupling, then the magnetic coupling between coil conductors is improved, but the volume of magnetic layers increases causing stress concentration and crack formation at interfaces
Solution Approach 1:
The magnetic layer is segmented into multiple parts: a first magnetic layer on the first nonmagnetic layer, a second magnetic layer on the second nonmagnetic layer, and a bridge magnetic layer connecting them. This segmentation reduces the continuous volume of magnetic material while maintaining coupling functionality through distributed magnetic paths.
Solution Approach 2:
The bridge magnetic layer is positioned to connect the first and second magnetic layers through the intermediate nonmagnetic layer, creating a nested structure where magnetic elements are embedded within the layered nonmagnetic matrix. This nesting allows magnetic coupling without requiring a large penetrating magnetic layer.
2Strength
If a magnetic layer penetrates through the center part of the coil conductors, then magnetic coupling is enhanced, but the volume of magnetic layers becomes difficult to control
Solution Approach 1:
The magnetic layer is divided into discrete segments (first magnetic layer, second magnetic layer, and bridge magnetic layer) that can be independently controlled in thickness and area. This segmentation enables precise control of total magnetic volume while maintaining effective coupling through the distributed structure.
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 inhibits crack formation, secures magnetic coupling between coil conductors, and simplifies the control of magnetic layer volume, enhancing the filter's performance and reliability.
Implementation Method 1
This enhances the magnetic coupling between the coil conductors, thereby improving the capability of eliminating common mode noises
Implementation Method 2
a stress caused by the difference in the amount of shrinkage between the nonmagnetic and magnetic layers is concentrated at their interfaces
Data Source
AI summary
A multilayer common mode filter is provided, which can inhibit cracks from occurring, while securing the magnetic coupling between coil conductors. Since magnetic layers are disposed in an inner region of spiral first and second coil conductors, the multilayer common mode filter can secure the magnetic coupling between the first and second coil conductors. In a columnar part including these magnetic layers, magnetic and nonmagnetic bodies are arranged alternately in the laminating direction, whereby the total volume of the magnetic layers in the inner region can be kept smaller than in the case where a magnetic layer penetrates through the inner region of the coil conductors. As a result, at the time of firing a matrix, the difference in the amount of shrinkage between the nonmagnetic and magnetic layers can be suppressed, so as to inhibit cracks from occurring at their interfaces.