Planar Dual-Coil Layout for Uniform Magnetic Coupling Control
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Solution Overview
Problem
The challenge in manufacturing coil components is to uniformly adjust the coupling coefficient and inductance characteristics due to variations in the manufacturing process, especially when multiple coil units are spaced apart, making it difficult to effectively control the degree of magnetic coupling and DC resistance characteristics.
Innovation Solution
A coil component design featuring first and second coil units with winding portions and extension portions surrounding cores, where the extension portions are arranged on the same plane to uniformly adjust the magnetic coupling, and the support substrate is embedded within a body with magnetic and insulating materials to enhance rigidity and adjust inductance and DC resistance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple coil units are spaced apart to adjust coupling coefficient, then coupling coefficient can be adjusted, but manufacturing process variations make it difficult to achieve uniform quality
Solution Approach 1:
The patent changes the geometric parameters of the coil units by adding extension portions that extend in a first direction, while the winding portions are spaced apart in a second direction perpendicular to the first direction. This parameter change allows independent control of coupling coefficient while maintaining manufacturing uniformity through standardized extension portion geometry.
Solution Approach 2:
The patent introduces a new spatial dimension by arranging extension portions to extend in a first direction while spacing winding portions apart in a perpendicular second direction. This dimensional separation allows the coupling coefficient to be adjusted through extension portion geometry without being constrained by manufacturing variations in the winding portion spacing.
2Adaptability or versatility
If coil units are disposed in various forms to adjust coupling coefficient, then coupling can be optimized, but inductance and DC resistance characteristics become difficult to control
Solution Approach 1:
The patent segments the coil unit into distinct functional portions: winding portions for generating magnetic fields and extension portions for adjusting coupling. This segmentation allows independent optimization of each portion's characteristics, making it easier to control overall inductance and DC resistance while achieving coupling optimization.
Solution Approach 2:
The patent applies local quality by giving different geometric characteristics to different portions of the coil unit. The winding portions maintain standardized geometry for consistent inductance and DC resistance, while the extension portions are specifically designed with adjustable geometry to optimize coupling coefficient without affecting the electrical characteristics of the winding portions.
3Adaptability or versatility
If coil units are spaced apart in various forms, then coupling coefficient can be adjusted, but the adjustment is difficult to achieve with uniform quality
Solution Approach 1:
The patent changes the controlling parameter for coupling adjustment from winding portion spacing (prone to manufacturing variation) to extension portion geometry (can be precisely controlled). By extending portions in a first direction while spacing winding portions in a perpendicular second direction, the coupling coefficient can be reliably adjusted through extension portion dimensions without being affected by manufacturing variations in spacing.
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 allows for more uniform adjustment of the coupling coefficient and improved inductance and DC resistance characteristics by arranging coil units on the same plane, effectively addressing the manufacturing variability issues and enhancing the overall performance of the coil component.
Implementation Method 1
first and second winding portions having at least one turn around the first and second cores, respectively
Implementation Method 2
first and second extension portions respectively extending from the first and second winding portions, each of the first and second extension portions surrounding the first and second cores
Data Source
AI summary
A coil component includes a support substrate, first and second coil units disposed on the support substrate and spaced apart from each other, and a body having a first core and a second core spaced apart from the first core. The first and second coil units include first and second winding portions having at least one turn around the first and second cores, respectively, and first and second extension portions respectively extending from the first and second winding portions, each of the first and second extension portions surrounding the first and second cores. The first and second winding portions are spaced apart from each other in a direction in which the first extension portion extends from the first winding portion.