Coil Component Structure for Compact High-Inductance Mounting
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Solution Overview
Problem
The increasing demand for smaller, higher-performance electronic components, particularly power inductors, has led to challenges in productivity and cost due to the need for circuit integration and the use of square-shaped chips, which require vision sorting equipment and result in decreased productivity and higher costs.
Innovation Solution
A coil component design featuring a hexahedral body with integrated coil portions, external electrodes, and insulating layers that simplifies manufacturing, reduces effective mounting area, and enhances inductance by increasing the magnetic body volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the chip size is reduced to meet miniaturization demands, then the component becomes more compact, but the inductance value decreases
Solution Approach 1:
The coil portion is wound around a magnetic core that is nested within the chip structure, maximizing the use of internal space. The magnetic body is positioned centrally with the coil portion surrounding it, creating a compact nested arrangement that maintains high inductance in a small volume.
Solution Approach 2:
The patent changes the parameters of the magnetic body including its permeability, volume, and shape to optimize inductance. By adjusting the magnetic body's properties and the coil's winding parameters, high inductance is achieved despite the reduced chip size.
2Shape
If square-shaped chips are used to meet design requirements, then the component achieves the desired shape, but productivity decreases and costs rise due to vision sorting equipment requirements
Solution Approach 1:
The patent employs asymmetric electrode arrangements and asymmetric coil winding patterns that are inherently compatible with square chips. This asymmetric design allows for simplified manufacturing processes that do not require complex vision sorting equipment, thereby maintaining productivity while achieving the desired square shape.
3Reliability
If the magnetic body volume is increased to improve inductance, then the inductance value increases, but the chip size and mounting area increase
Solution Approach 1:
The magnetic body is nested within the chip structure with the coil portion wound around it, maximizing space utilization. This nested arrangement allows the magnetic body to occupy the maximum possible volume within the chip's footprint without increasing the external dimensions, thereby improving inductance while maintaining a compact mounting area.
Solution Approach 2:
The patent optimizes the magnetic body's vertical dimension (height) to increase its volume without expanding the horizontal footprint. By utilizing the third dimension effectively, the magnetic body achieves greater volume for higher inductance while the chip's mounting area remains compact.
4Reliability
If multiple insulating layers are added to improve electrical insulation, then the insulation reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple insulating layers into an integrated insulation structure that is formed as a single unit or pre-assembled component. This merging approach maintains the electrical insulation reliability of multiple layers while simplifying the manufacturing process by reducing the number of separate application steps.
Solution Approach 2:
The insulating layers are designed to serve multiple functions simultaneously: electrical insulation, mechanical support, and structural stability. This multi-functionality reduces the need for additional specialized components and simplifies the overall manufacturing process while maintaining insulation reliability.
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 a lightweight, compact, and efficient coil component with improved productivity and reduced man-hours, while maintaining reliable electrical connections and insulating properties.
Implementation Method 1
a coil portion disposed within the body
Implementation Method 2
a volume of a magnetic body is increased to increase inductance
Data Source
AI summary
A coil component includes: a body having one surface and the other surface opposing each other and a plurality of walls connecting the one surface and the other surface to each other; a coil portion disposed within the body; first and second external electrodes disposed on the one surface of the body while being spaced apart from each other and connected to the coil portion; a first insulating layer disposed on the other surface of the body and extending to at least a portion of each of the plurality of walls of the body; and a second insulating layer disposed on the one surface of the body.