Thin-Film Coil Pattern Layout for Low-Resistance Inductors
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Solution Overview
Problem
High aspect ratio coil patterns in thin film inductors lead to a step problem due to a large number of turns, limiting the implementation of high-capacity products and increasing direct current resistance.
Innovation Solution
A coil electronic component with a coil pattern aspect ratio less than 1, where the width of the coil pattern is enlarged relative to its thickness, allowing for a low profile design and reduced direct current resistance by increasing the cross-sectional area while maintaining the number of turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high aspect ratio (coil thickness/coil line width) is implemented to increase the number of turns, then the inductance is improved, but a step occurs and the manufacturing precision deteriorates
Solution Approach 1:
The patent changes the aspect ratio parameter of the coil pattern from high (greater than 1) to low (less than 1), specifically setting the width W1 of the coil pattern to satisfy 0.8W2≤W1≤W2 where W2 is the width of external electrodes. This parameter change allows achieving sufficient inductance with fewer turns, thereby preventing step formation and improving manufacturing precision while maintaining reliability
2Reliability
If a high aspect ratio coil pattern is used, then the number of turns is increased, but the direct current resistance increases and productivity decreases
Solution Approach 1:
By changing the aspect ratio parameter to less than 1 and optimizing the width relationship (0.8W2≤W1≤W2), the patent achieves sufficient inductance with fewer turns. This reduces the total length of the coil pattern, thereby reducing direct current resistance and improving energy efficiency and productivity
3Reliability
If a high aspect ratio coil pattern is implemented, then more turns are achieved, but the profile height increases and the shape uniformity deteriorates
Solution Approach 1:
The patent changes the aspect ratio to less than 1 and sets the width W1 to satisfy 0.8W2≤W1≤W2, which enables achieving sufficient inductance with fewer turns. This reduces the profile height and improves the uniformity of the coil pattern shape, eliminating the step problem while maintaining inductance
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 effectively reduces direct current resistance and improves inductance by increasing the cross-sectional area of the coil portion, preventing step formation and enhancing the uniformity of the pattern, thus enabling the production of high-capacity products with low profile characteristics.
Implementation Method 1
first and second external electrodes disposed on external surfaces of the body and connected to both ends of the coil pattern, respectively. The first and second external electrodes include a first plating layer disposed on an end surface of the body and a conductive resin layer covering the first plating layer
Data Source
AI summary
A coil electronic component includes a body, a coil portion disposed in the body and including a support substrate and a coil pattern disposed on at least one surface of the support substrate and forming at least one turn, and first and second external electrodes disposed on external surfaces of the body and connected to both ends of the coil pattern, respectively. The first and second external electrodes include a first plating layer disposed on an end surface of the body and a conductive resin layer covering the first plating layer and extending to a main surface of the body, to be connected to the coil pattern. An aspect ratio of the coil pattern is less than 1 and a width W1 of the coil pattern satisfies 0.8W2≤W1≤W2 as compared with a width W2 of the first and second external electrodes.