Coupled Inductor Layout With Shorter Electrodes for Lower DC Resistance
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Solution Overview
Problem
In coupled inductor structures, the DC resistance of coil electronic components increases with longer external electrodes, which affects the efficiency of power management in mobile devices, necessitating a method to reduce this resistance.
Innovation Solution
The design includes a magnetic body with a first and second core, where the first and second coils are embedded, and external electrodes are positioned on one surface, with a support member connecting the coils. The distance from the coils to the surface and the thickness of cover layers are optimized to reduce DC resistance, with the difference in distances ranging from 5 μm to 160 μm, and the cover layer thicknesses are adjusted to minimize electrode lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the length of external electrodes is increased to connect the coils, then the connectivity is improved, but the DC resistance increases
Solution Approach 1:
The patent positions all external electrodes on a single surface of the magnetic body rather than distributing them across multiple surfaces. This dimensional reorganization allows the electrodes to connect to coils through shorter lateral paths within the magnetic body, reducing the effective length of current paths and thereby lowering DC resistance while maintaining connectivity.
Solution Approach 2:
The patent optimizes the geometric parameters of the magnetic body, specifically setting the distance from coils to one surface (first surface) as larger than the distance to the opposite surface (second surface). This asymmetric parameter configuration minimizes the path length between coils and external electrodes, directly reducing DC resistance while preserving electrical connectivity.
2Loss of energy
If the distance from coils to surface is optimized to reduce DC resistance, then the electrode length is reduced, but the structural symmetry is disrupted
Solution Approach 1:
The patent deliberately introduces asymmetry into the magnetic body structure by making the distance from the coils to the first surface larger than the distance to the second surface. This asymmetric design is not a deviation but a purposeful feature that enables shorter external electrode paths on the second surface, thereby reducing DC resistance while maintaining functional symmetry in electrical performance.
Data Source
AI summary
A coil electronic component may include a magnetic body that has a first surface and a second surface facing each other, a first coil embedded in the magnetic body and wound around a first core, a second coil embedded in the magnetic body and wound around a second core that is spaced apart from the first core, a first external electrode and a second external electrode disposed on the second surface of the magnetic body and connected to the first coil, and a third external electrode and a fourth external electrode disposed on the second surface of the magnetic body and connected to the second coil, and a first distance from the first coil and the second coil to the first surface is larger than a second distance from the first coil and the second coil to the second surface.