Multilayer Polyimide Coil Support for Thin Magnetic Components
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Solution Overview
Problem
The miniaturization and thinning of coil components in electronic devices pose challenges in maintaining magnetic properties and structural stability, as reducing the thickness of the body can lead to compromised magnetic flux flow and structural support.
Innovation Solution
A coil component design featuring a support member with a multilayer structure of polyimide layers, where the first layer is a thermoplastic polyimide and the second layer is a polyimide, with specific surface roughness conditions to enhance coupling with the coil, ensuring structural stability and magnetic flux flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the body is reduced for miniaturization, then the size of the coil component is reduced, but the magnetic properties deteriorate due to reduced cover region thickness affecting magnetic flux flow
Solution Approach 1:
The patent changes the physical and chemical parameters of the support member by controlling its thickness within a specific range (3 μm to 10 μm) and adjusting its surface roughness (Ra: 0.1 to 0.5 μm, Rz: 1.0 to 2.5 μm). These parameter optimizations allow the support member to maintain structural integrity and magnetic flux flow characteristics even when the overall component thickness is reduced for miniaturization.
Solution Approach 2:
The support member is constructed as a composite structure with multiple polyimide layers (first layer and second layer), creating a multi-layer composite material system. This composite structure provides enhanced mechanical strength and magnetic flux guidance capabilities while maintaining thin overall dimensions, resolving the contradiction between miniaturization and magnetic property preservation.
2Volume of moving object
If the thickness of the support member is reduced for miniaturization, then the size of the coil component is reduced, but the structural stability deteriorates making it difficult to stably support the coil
Solution Approach 1:
The patent optimizes the support member thickness to a specific range (3 μm to 10 μm) and controls surface roughness parameters (Ra: 0.1 to 0.5 μm, Rz: 1.0 to 2.5 μm) to achieve the best balance between miniaturization and structural stability. These parameter changes ensure the support member can stably hold the coil while maintaining reduced overall dimensions.
Solution Approach 2:
The support member features differentiated local properties through its multi-layer construction, where the first layer and second layer may have different characteristics optimized for specific functions. This local quality differentiation allows the thin support member to provide adequate structural stability at critical locations while maintaining overall miniaturization.
3Reliability
If the ratio of magnetic material in the core is increased to maintain characteristics during miniaturization, then the magnetic properties are improved, but the frequency characteristics change due to body strength and insulation limits
Solution Approach 1:
The patent optimizes the thickness of the support member within the range of 3 μm to 10 μm to achieve the best balance between magnetic flux guidance and frequency characteristics. This parameter optimization allows the coil component to maintain good magnetic properties while avoiding degradation of frequency response that would occur with excessive magnetic material concentration.
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 design achieves improved structural stability and maintains magnetic properties while allowing for miniaturization, ensuring smooth magnetic flux flow and stable support of the coil component.
Implementation Method 1
a first average surface roughness, Ra, of the surface of the support member on which the coil is disposed is 0.1 to 0.5 μm
Data Source
AI summary
A coil component includes a body, a support member disposed within the body, a coil disposed on at least one of a first surface and a second surface of the support member opposing each other, and an external electrode disposed on the body and connected to the coil, wherein the support member includes a first layer and a second layer respectively including polyimide, and an average surface roughness of the surface of the support member on which the coil is disposed is 0.1 to 0.5 μm in Ra value.