Coil Component Dummy Patterns for Mounting Stability

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Solution Overview

Problem

Inductors used in electronic devices often deform or get damaged when mounted on printed circuit boards, especially as devices become smaller and more high-performance, leading to research for solutions to minimize deformation and improve mounting stability.

Innovation Solution

A coil component design featuring a body with a substrate, coil portion, lead-out portion, and dummy portion, where the dummy portion forms an X-shape and is spaced apart from the coil portion, with an insulating layer covering the coil and dummy portions to prevent deformation and improve mounting stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the coil component is made smaller to meet high-performance device requirements, then the size of the electronic device is reduced, but the coil is more prone to deformation and damage during mounting

Engineering Contradiction:

Improvesize of coil componentVSAvoidmounting stability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The dummy patterns are formed in advance during the manufacturing process, before mounting. These dummy patterns pre-establish the stress distribution characteristics that will counteract deformation forces during subsequent mounting operations, preventing coil deformation before it occurs

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dummy patterns create preliminary counteracting forces against the deformation that would occur during mounting. By having these compensatory structures in place before mounting, the coil is pre-protected from the harmful deformation effects that would otherwise occur during the mounting process

Inventive Principle:

Principle #9Preliminary anti-action

2Volume of moving object

If the coil component is made thinner to reduce size, then the volume is reduced, but the structural strength decreases leading to increased deformation

Engineering Contradiction:

Improvevolume of coil componentVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The dummy patterns are positioned asymmetrically at the four corners of the coil structure, with each dummy pattern located at a different corner position. This asymmetric distribution creates balanced counteracting forces that compensate for the reduced structural strength in thinner designs, preventing deformation while maintaining compact dimensions

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The dummy patterns are strategically placed at the four corners where stress concentration occurs during mounting. By concentrating the compensatory structures at these specific locations rather than uniformly distributing them, the design provides localized reinforcement exactly where needed to prevent deformation in the thinned structure

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20230170133A1Coil component

Publication Date: 2023.06.01 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A coil component includes a body including a first surface and a plurality of side surfaces respectively connected to the first surface, a substrate disposed in the body, a coil portion disposed in the body, a lead-out portion disposed in the body and connected to the coil portion, and a dummy portion spaced apart from the lead-out portion. The body includes four corners, at each of which two adjacent side surfaces of the first to fourth side surfaces are in contact with each other, and the dummy portion includes first to fourth dummy patterns respectively disposed outside the coil portion and extending toward the four corners of the body.