Inductor with Embedded Lead Frame for Thin Profile
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Solution Overview
Problem
Conventional inductors integrated with IC chips using existing methods result in increased height, making it difficult to achieve a thin design while maintaining specific inductance values, and often lack high welding strength.
Innovation Solution
The inductor design embeds a conducting wire within a core and utilizes a lead frame with an embedded portion and welding platform to reduce total height and enhance welding strength, allowing for integration with IC chips using system-in-package technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lead is extended from a lower core of an inductor to be welded on a welding foot of a circuit board, then welding strength is improved, but the total height of the inductor increases
Solution Approach 1:
The lead frame is embedded within a recess portion of the lower core, with the embedded portion having a height less than the core thickness. This nesting arrangement allows the lead frame to be integrated into the core structure rather than adding to it, reducing the total height while maintaining welding capability through the embedded connection.
2Strength
If an external lead frame is connected under a lower core of an inductor to be welded on a lead frame of an IC chip, then welding strength is improved, but the total height of the inductor increases
Solution Approach 1:
The lead frame is positioned within a recess portion of the lower core, creating a nested configuration where the lead frame does not extend beyond the core's outer surface. This eliminates the height contribution of an external lead frame while preserving the welding function through the embedded lead frame structure.
Solution Approach 2:
Instead of extending the lead frame vertically beneath the core (adding height), the lead frame is embedded horizontally within the recess portion of the core. This dimensional repositioning maintains the welding connection capability while eliminating the vertical space occupation.
3Strength
If the lower core has a specific thickness to keep structure strength, then structural integrity is improved, but the total height of the inductor increases
Solution Approach 1:
A recess portion is created locally within the lower core structure, allowing the lead frame to be embedded in this specific region. This localized modification maintains the overall structural integrity of the core while providing space for the lead frame connection, avoiding the need to increase the entire core thickness.
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
This design effectively reduces the total height of the inductor when integrated with IC chips, enabling thin product designs and achieving high welding strength, thus improving the connection and performance of electronic products.
Implementation Method 1
An inductor is a passive electrical component that can store energy in a magnetic field created by the electric current passing through it. An inductor's ability to store magnetic energy is measured by its inductance. Typically an inductor is a conducting wire shaped as a coil, the loops helping to create a strong magnetic field inside the coil due to Faraday's Law of Induction.
Implementation Method 2
Inductance is an effect resulting from the magnetic field that forms around a current-carrying conductor which tends to resist changes in the current.
Implementation Method 3
The number of loops, the size of each loop, and the material it is wrapped around all affect the inductance. For example, the magnetic flux linking these turns can be increased by coiling the conductor around a material with a high permeability such as ferrite magnetism.
Data Source
AI summary
An inductor includes a first core, a conducting wire, a second core and a first lead frame. There is an accommodating space formed on a first side of the first core and there is a recess portion formed on a second side of the first core, wherein the first side is opposite to the second side. The first core has a first height. The conducting wire is disposed in the accommodating space. The second core is disposed on the first side of the first core and covers the accommodating space. The first lead frame has an embedded portion embedded in the recess portion. The embedded portion has a second height. After embedding the embedded portion in the recess portion of the first core, a total height of the embedded portion and the first core is smaller than the sum of the first height and the second height.