Coil Component With Variable Winding Turn Width
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Solution Overview
Problem
The miniaturization and thinning of coil components in electronic devices pose challenges in maintaining the number of turns and cross-sectional area of coil patterns while reducing electrical overstress, leading to development and plating defects during pattern wall formation.
Innovation Solution
A coil component design featuring a support member with pattern walls and a coil pattern where the intermediate winding turn width is larger than the innermost and outermost turns, utilizing a manufacturing method that includes forming a plating seed, pattern walls, and a coil pattern extending between these walls to address defects in development and plating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component is miniaturized and thinned, then the size of the coil component is reduced, but the number of turns and cross-sectional area of the coil pattern cannot be maintained
Solution Approach 1:
The patent applies local quality by making the intermediate winding turn wider than the innermost and outermost winding turns. This localized variation in width compensates for the reduced overall size, allowing the coil pattern to maintain sufficient cross-sectional area and number of turns while achieving miniaturization of the coil component.
Solution Approach 2:
The patent changes the geometric parameters of the coil pattern by varying the width of different winding turns. Specifically, the intermediate winding turn is designed with a larger width parameter, while the innermost and outermost turns have smaller width parameters, optimizing the balance between size reduction and electrical performance.
2Volume of moving object
If the interval between coil patterns is decreased, then the coil component size is reduced, but electrical overstress increases
Solution Approach 1:
The patent applies local quality by providing pattern walls at specific locations between the innermost and outermost winding turns. These pattern walls are strategically positioned to provide electrical isolation and stress distribution exactly where needed, rather than uniformly across all intervals, thus reducing electrical overstress while maintaining compact dimensions.
3Volume of moving object
If the aspect ratio of the coil pattern is increased, then the coil component can be miniaturized, but development defects and plating defects occur
Solution Approach 1:
The patent applies local quality by making the intermediate winding turn wider than the innermost and outermost turns. This localized width increase improves the aspect ratio in critical areas, enabling miniaturization while the varied width distribution prevents uniform stress concentration that would cause development and plating defects during manufacturing.
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 reduces development and plating defects, enhancing the aspect ratio of the coil pattern and improving inductance while minimizing electrical overstress, thus achieving equivalent performance to traditional coil components.
Implementation Method 1
forming a coil pattern extending between the pattern walls on the support member and including a plurality of winding turns
Data Source
AI summary
A coil component includes: a body in which a coil part is embedded, wherein the coil part includes: a support member; a pattern wall disposed on the support member; and a coil pattern extending between the pattern walls on the support member and including a plurality of winding turns. A width of an intermediate winding turn between innermost and outermost winding turns, among the plurality of winding turns of the coil pattern, is larger than widths of the innermost and outermost winding turns.