Bond-Wire Inductor Structure for Low-Resistance Surface Mounting

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Solution Overview

Problem

Existing inductive devices for surface mounting in electronic devices are limited by high DC resistance, high manufacturing complexity, and high costs, while also failing to meet the form factor requirements for surface mounted devices (SMDs) when used with power management integrated circuits (PMICs) and IC packages.

Innovation Solution

The development of an inductive device with a bond-wire structure comprising a first and second conductive structure and a bond-wire structure forming a coil, which is compatible with the SMD form factor, offering high inductance and low DC resistance, and is manufactured using a wedge-bonding process with a magnetic molding portion to enhance performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional inductive devices are used for surface mounting, then the form factor requirements for SMDs can be met, but the DC resistance is high and manufacturing complexity is high

Engineering Contradiction:
ImproveDC resistanceVSAvoidmanufacturing complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The inductive device is segmented into multiple conductive structures (first conductive structure, second conductive structure, third conductive structure, fourth conductive structure) that form separate coil windings. Each conductive structure is independently formed and then interconnected through conductive vias to create the complete inductor. This segmentation allows for simplified manufacturing of individual components while achieving low DC resistance through the integrated multi-structure design.

Inventive Principle:
Principle #1Segmentation

2Ease of manufacture

If traditional inductive devices are used for surface mounting, then the form factor requirements for SMDs can be met, but the manufacturing costs are high

Engineering Contradiction:
Improvemanufacturing costVSAvoidDC resistance
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The inductive device merges multiple conductive structures into a single integrated component that can be surface mounted as one unit. The first, second, third, and fourth conductive structures are interconnected through conductive vias to form a unified inductor with low DC resistance. This merging approach maintains SMD form factor compatibility while reducing manufacturing cost through integration and simplified assembly processes.

Inventive Principle:
Principle #5Merging (Combining)

3Adaptability or versatility

If higher inductance is achieved through traditional designs, then the inductance requirement is met, but the device size increases beyond SMD form factor

Engineering Contradiction:
ImproveinductanceVSAvoiddevice area
Core Design Contradiction:
Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The conductive structures utilize three-dimensional routing with conductive vias that extend vertically through the substrate, transitioning the design from a purely two-dimensional surface layout to a three-dimensional structure. This dimensional change allows the magnetic flux to be confined within a smaller footprint area while maintaining high inductance through the vertical component of the magnetic path, thus meeting SMD form factor requirements.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 solution provides an inductive device with reduced DC resistance and manufacturing complexity, maintaining high inductance and compatibility with existing PCB layouts, thus enhancing the performance and reducing costs for mass production.

Implementation Method 1

a coil structure of the inductor of the inductive device comprises the arch portion, the first elongated portion, and the second elongated portion

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250349459A1Inductive device for surface mounting
Publication Date: 2025.11.13 QUALCOMM INC
  • US20250349459A1 patent drawing
  • US20250349459A1 patent drawing
  • US20250349459A1 patent drawing

AI summary

Disclosed are techniques for a structure of an inductive device. In an aspect, an inductive device includes a first conductive structure, a second conductive structure, and a bond-wire structure. The first conductive structure has a first anchor portion and a first elongated portion. The second conductive structure has a second anchor portion and a second elongated portion. The bond-wire structure has a first bottom portion mounted on the first elongated portion, a second bottom portion mounted on the second elongated portion, and an arch portion between the first bottom portion and the second bottom portion. A coil structure of an inductor of the inductive device comprises the arch portion, the first elongated portion, and the second elongated portion.