Inductor Component With Columnar Wiring For Solder Prevention
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Solution Overview
Problem
Conventional inductor components face limitations when incorporating multiple inductors due to restrictions on the formation region of internal electrodes, which affect the DC resistance and design flexibility, making them unsuitable for mounting multiple inductors without compromising solder prevention.
Innovation Solution
The inductor component design includes multiple columnar wirings and external terminals with an insulating film, allowing for reduced restrictions on the formation region of internal electrodes, improved adhesion, and enhanced conductivity, while maintaining the shortest distance between terminals to prevent short-circuits, enabling the incorporation of multiple inductors with increased design freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the external terminals are made larger than the end surfaces of internal electrodes to ensure solder prevention, then the reliability is improved, but the area available for internal electrode formation is reduced
Solution Approach 1:
The patent transitions from a planar arrangement where external terminals directly overlay internal electrodes to a three-dimensional configuration using columnar wirings that extend vertically from internal electrodes through the magnetic composite body. This vertical dimension allows external terminals to be positioned at the top surface while internal electrodes can be arranged in the lower region, effectively decoupling the horizontal spacing requirements for solder prevention from the internal electrode formation area.
Solution Approach 2:
The patent introduces columnar wirings as intermediary elements that connect internal electrodes to external terminals. These columnar wirings act as mediators that extend the electrical connection vertically through the magnetic composite body, allowing the external terminals to be larger for reliable soldering while the internal electrodes can be positioned closer together since they are not directly exposed on the top surface.
2Reliability
If the shortest distance between adjacent external terminals is ensured at a certain level to prevent short circuit, then the reliability is improved, but the design freedom and DC resistance characteristics are worsened
Solution Approach 1:
The patent resolves this contradiction by moving the spacing constraint from the horizontal plane to the vertical dimension. The columnar wirings provide vertical separation and insulation, allowing external terminals to be positioned closer together horizontally while maintaining adequate isolation through the vertical columnar structure and surrounding insulating material.
Solution Approach 2:
The patent uses a composite structure combining magnetic composite body material with insulating material to surround and separate the columnar wirings. This composite approach provides both the structural support needed for the inductor and the electrical insulation required to prevent short circuits between adjacent terminals, enabling closer terminal spacing while maintaining reliability.
3Reliability
If the shortest distance between internal electrodes is increased to ensure solder prevention, then the reliability is improved, but the DC resistance increases and design freedom is reduced
Solution Approach 1:
The patent eliminates the direct horizontal spacing requirement between internal electrodes by introducing vertical columnar wirings. This allows internal electrodes to be positioned closer together in the horizontal plane, reducing the number of turns needed in the spiral wiring and thereby reducing DC resistance, while the vertical columnar structure ensures proper isolation for solder prevention.
Data Source
AI summary
An inductor component comprises an element body; first and second inductors in the body; first and second columnar wirings in the body with end surfaces exposed from a first principal surface of the body and electrically connected to the first inductor; third and fourth columnar wirings in the body with end surfaces exposed from the first principal surface and electrically connected to the second inductor; first through fourth external terminals contacting the end surfaces of the first through fourth columnar wirings, respectively; and an insulating film on the first principal surface covering a portion of the end surface of the first and third columnar wiring not contacting the first and third terminals, respectively. The first terminal is closer to the third terminal than the fourth terminal, and a shortest distance between the first and third terminals is longer than a shortest distance between the first and third columnar wirings.