Stacked Coil Component with Gap Member for Inductance Control
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Solution Overview
Problem
The increasing demand for thinner, high-efficiency, and miniaturized power inductors with adjustable coupling values for multifunctional electronic devices poses a challenge in achieving optimal performance and reduced mounting area, especially due to the complexity introduced by integrated chip operations.
Innovation Solution
A coil component design featuring a magnetic body with first and second coil patterns on substrates, external electrodes, and a gap member between the substrates to adjust inductance values by interfering with magnetic flux, allowing for various coupling values in a power inductor array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of power inductor is reduced to meet miniaturization demands, then mounting area is reduced, but inductance value becomes difficult to maintain
Solution Approach 1:
The patent transitions from a single-layer planar coil structure to a three-dimensional stacked structure with multiple substrates (first substrate with first coil pattern, second substrate with second coil pattern). This vertical stacking enables maintaining sufficient inductance value while reducing the planar mounting area, effectively resolving the contradiction between miniaturization and inductance maintenance.
Solution Approach 2:
The patent employs a composite magnetic body structure combining ferrite magnetic bodies with magnetic cores on each substrate. This composite approach allows achieving high inductance density in a compact form factor, enabling both miniaturization and reliable inductance value maintenance simultaneously.
2Area of stationary object
If multiple coil patterns are integrated to form power inductor array, then mounting area is reduced, but coupling control becomes complex
Solution Approach 1:
The patent divides the power inductor array into independently controllable units: first coil pattern and second coil pattern on separate substrates. Each coil can be independently controlled, allowing flexible adjustment of coupling values between 0 and 1 without increasing overall mounting area. This segmentation simplifies coupling control compared to densely integrated arrays.
Solution Approach 2:
The patent introduces a magnetic core as an intermediary element between the first and second coil patterns. By adjusting the magnetic core's position or properties, coupling between coils can be precisely controlled. This intermediary mechanism provides intuitive and effective coupling control while maintaining compact array structure.
3Length of stationary object
If substrate thickness is reduced to achieve thinner profile, then overall thickness is reduced, but structural stability and magnetic flux control deteriorate
Solution Approach 1:
The patent compensates for reduced substrate thickness by utilizing the vertical stacking dimension. Multiple thin substrates are stacked with magnetic cores and coil patterns arranged in three dimensions. This approach maintains overall structural stability and magnetic flux control through spatial distribution rather than relying on single substrate thickness.
Solution Approach 2:
The patent uses composite structures combining thin substrates with ferrite magnetic bodies and magnetic cores. This composite design provides structural reinforcement and improved magnetic flux control despite reduced substrate thickness, achieving both thin profile and structural stability simultaneously.
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 enables efficient miniaturization of power inductors, providing adjustable coupling values and improved performance by controlling inductance through the gap member's interference, thus meeting the demands of high-frequency data transmission in complex electronic systems.
Implementation Method 1
a gap member disposed between the two substrates while being located in at least one of upper and lower regions of a magnetic body in a thickness direction
Data Source
AI summary
A coil component includes a magnetic body including first and second coil patterns respectively disposed on first surfaces of two substrates spaced apart from each other and having cores and third and fourth coil patterns respectively disposed on second surfaces of the two substrates; and first to fourth external electrodes disposed on outer peripheral surfaces of the magnetic body and connected to the first to fourth coil patterns, respectively. A gap member is disposed between the two substrates while being located in at least one of upper and lower regions of the magnetic body in a thickness direction.