Coil Component Trench Segmentation for Structural Stability

Solution Overview

Problem

The challenge in miniaturizing and thinning coil components for electronic devices is maintaining structural stability while achieving a high aspect ratio, which is crucial for maintaining electrical characteristics and preventing bending or collapse during manufacturing.

Innovation Solution

The coil component incorporates a coil pattern with trenches formed on its surfaces, aligned either symmetrically or asymmetrically, and a support member, where the trenches can be filled with the same material as the body or insulating layer, enhancing structural stability and electrical connectivity, and the coil patterns are embedded in a magnetic material dispersed in a resin, with an aspect ratio of 3 to 20.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the aspect ratio of the coil pattern is increased to achieve miniaturization and thinning, then the coil component can be made smaller and thinner, but the structural stability of the coil pattern deteriorates causing bending or collapse

Engineering Contradiction:

Improvecoil component sizeVSAvoidcoil pattern stability

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

The coil pattern is divided into multiple segments by forming trenches between adjacent turns. This segmentation prevents the coil pattern from bending or collapsing by creating discrete sections that are structurally independent, allowing each segment to maintain its shape while achieving an overall high aspect ratio configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Trenches are formed at specific locations between adjacent turns of the coil pattern, creating local structural modifications rather than uniform changes throughout. This localized approach provides structural support where needed while maintaining the overall high aspect ratio geometry of the coil pattern.

Inventive Principle:

Principle #3Local quality

2Stability of the object's composition

If trenches are formed in the coil pattern to improve structural stability, then the coil pattern stability is improved, but the device complexity increases

Engineering Contradiction:

Improvecoil pattern stabilityVSAvoidcoil pattern structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The coil pattern is divided into multiple segments by forming trenches between adjacent turns. This segmentation prevents the coil pattern from bending or collapsing by creating discrete sections that are structurally independent, allowing each segment to maintain its shape while achieving an overall high aspect ratio configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Trenches are formed at specific locations between adjacent turns of the coil pattern, creating local structural modifications rather than uniform changes throughout. This localized approach provides structural support where needed while maintaining the overall high aspect ratio geometry of the coil pattern.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11437173B2Coil component

Publication Date: 2022.09.06 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A coil component includes a body, a coil portion embedded in the body, and external electrodes electrically connected to the coil portion. The coil portion includes coil patterns having trenches formed in surfaces thereof. The trenches extend through a partial thickness of the coil portion, and are located at aligned locations in adjacent windings of the coil portion. A method of forming the coil component includes forming a mask pattern having a coil shaped opening and including a plurality of bridges extending across the coil shaped opening in the mask pattern.