Coil Component With Anchored Pattern Walls
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Solution Overview
Problem
The miniaturization and thinning of coil components in electronic devices pose challenges in maintaining the number of windings and cross-sectional area while reducing electrical overstress, as existing technologies struggle to increase the aspect ratio of coil patterns without risking short-circuits or efficiency limitations.
Innovation Solution
The use of pattern walls with anchors formed in trenches on a support member to stabilize coil patterns, allowing for increased aspect ratios and reduced electrical overstress by serving as plating growth guides and preventing lifting or voids between the pattern walls and the support member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component is miniaturized and thinned, then the size is reduced, but the number of windings and cross-sectional area cannot be maintained
Solution Approach 1:
The patent transitions from planar coil patterns to three-dimensional vertical structures by forming pattern walls with anchors in trenches. This dimensional change allows the coil to achieve greater effective length and cross-sectional area within a reduced footprint, resolving the contradiction between miniaturization and maintaining winding quantity.
Solution Approach 2:
The pattern walls are formed by nesting structures within trenches on the support member, creating anchored vertical profiles that extend upward. This nested configuration enables the coil pattern to utilize vertical space efficiently, maintaining substantial cross-sectional area while reducing the horizontal footprint of the component.
2Power
If the aspect ratio of the coil pattern is increased, then the inductance is improved, but electrical overstress and short-circuit risk increase
Solution Approach 1:
The patent applies different structural qualities to different regions: the pattern walls have narrow widths for high aspect ratio and inductance, while the anchors in trenches provide localized reinforcement for mechanical stability and electrical isolation. This local differentiation allows high inductance without proportionally increasing electrical overstress vulnerability.
Solution Approach 2:
The anchors formed in trenches during the plating process provide pre-established mechanical and electrical support before the full coil structure is completed. This beforehand cushioning prevents lifting and void formation, ensuring that high aspect ratio structures maintain reliability even under electrical overstress conditions.
3Area of stationary object
If the interval between coil patterns is reduced, then the density is increased, but electrical overstress increases
Solution Approach 1:
The pattern walls serve as intermediary structures between adjacent coil patterns, providing physical separation and electrical isolation. The anchored configuration of these intermediary walls ensures they remain stable even when spacing is reduced, preventing electrical overstress while maintaining high density.
4Ease of manufacture
If pattern walls are formed without anchors, then the manufacturing is simpler, but lifting and voids occur
Solution Approach 1:
The anchors are formed in trenches during the plating seed layer formation, before the main pattern wall structure is built. This preliminary action ensures that when the pattern walls are formed, they have pre-established attachment points, preventing lifting and voids without significantly complicating the overall manufacturing process.
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 approach ensures stable coil component characteristics, reduces the risk of short-circuits and electrical overstress, and allows for higher inductance and efficiency by maintaining the structural integrity of the coil patterns within a limited space.
Implementation Method 1
forming a plating seed layer on one surface of a support member, forming trenches in the support member, forming pattern walls extending from the trenches, and forming coil patterns extending between the pattern walls on the support member by using a plating seed left after etching the plating seed layer
Data Source
AI summary
A coil component includes a body in which a coil part is embedded. The coil part includes a support member having trenches, pattern walls extending from the trenches in the support member, and coil patterns extending between the pattern walls on the support member.