Stacked Coil Component Layout for Higher Inductance
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Solution Overview
Problem
Existing coil components struggle to achieve high inductance due to limited volume of the magnetic element body.
Innovation Solution
The coil component design includes a magnetic element body with a increased volume by embedding conductor layers stacked through insulating resin layers, where the magnetic element body is disposed in separation areas overlapping the lead-out pattern, enhancing the magnetic element body's volume and reducing leakage flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the volume of the magnetic element body is increased to increase inductance, then the inductance is improved, but the device complexity increases due to the need for multiple conductor layers and insulating resin layers
Solution Approach 1:
Multiple conductor layers are nested within the magnetic element body, with each conductor layer containing a coil pattern and connection patterns. The conductor layers are embedded in the magnetic element body along the stacking direction, creating a nested structure that maximizes the use of magnetic element volume while maintaining a compact form factor. This nesting approach allows multiple functional layers to coexist within the same spatial envelope, increasing inductance without proportionally increasing external dimensions.
Solution Approach 2:
The patent transitions from a planar two-dimensional coil structure to a three-dimensional stacked structure by arranging multiple conductor layers along the stacking direction (vertical dimension). The coil patterns in different layers are positioned at different heights, creating a three-dimensional magnetic path that increases the effective volume of the magnetic element body. This dimensional transition allows the magnetic field to utilize the full three-dimensional space, thereby increasing inductance more effectively than a single-layer planar design.
2Loss of energy
If the volume of the magnetic element body is increased to increase inductance, then the inductance is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The coil structure is segmented into multiple discrete conductor layers, each with its own coil pattern and connection patterns. Each conductor layer is independently formed and then stacked with insulating resin layers in between. This segmentation allows for modular manufacturing where each layer can be prepared separately with standard precision requirements, and then assembled through lamination. The segmentation approach reduces the overall manufacturing precision requirement compared to attempting to create a single complex three-dimensional coil structure in one step.
Solution Approach 2:
The conductor patterns and connection patterns are preliminarily formed on conductor layers before stacking. The outer peripheral ends of coil patterns are pre-positioned to connect to connection patterns, and lead-out patterns are pre-configured in specific conductor layers. This preliminary formation of patterns and connection points allows for standardized manufacturing processes where precision is established at each layer formation stage, making the overall assembly process more manageable and less demanding on final assembly precision.
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 effectively increases the inductance of the coil component by maximizing the volume of the magnetic element body, while minimizing leakage flux, thereby improving the component's performance.
Implementation Method 1
a plurality of conductor layers embedded in the magnetic element body and stacked through insulating resin layers. The plurality of conductor layers each include a coil pattern having a coil axis extending in parallel to the mounting surface
Data Source
AI summary
Disclosed herein is a coil component that includes plural conductor layers embedded in the magnetic element body. Each of the conductor layers includes a coil pattern, and first and second connection patterns exposed from the magnetic element body. The conductor layers includes a first conductor layer positioned at one end portion in the stacking direction, a second conductor layer positioned at the other end portion in the stacking direction, and one or more third conductor layers positioned between the first and second conductor layers. In the second conductor layer, an outer peripheral end of the coil pattern is connected to the second connection pattern through a lead-out pattern. In at least one of the first to third conductor layers, the magnetic element body is disposed in a separation area overlapping the lead-out pattern in the stacking direction.