Inductor Insulating Layer Shape for Higher Magnetic Layer Volume
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inductor components face a limitation in increasing the inductance value due to the restricted width of the insulating layer, which prevents the volume of the magnetic layer from being maximized, thereby hindering the improvement of inductance.
Innovation Solution
The inductor component features a trapezoidal-shaped insulating layer with a narrower first end surface compared to the second end surface, allowing for a reduced volume of the insulating layer and an increased volume of the magnetic layer, achieved through photolithography and baking processes, enabling improved inductance values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating layer is formed with a rectangular shape having the same width as the coil wiring formation area, then the insulating layer adequately covers the coil wiring, but the volume of the magnetic layer cannot be increased to improve inductance value
Solution Approach 1:
The insulating layer is designed with an asymmetric trapezoidal cross-section where the width at the first end surface (away from base layer) is narrower than the width at the second end surface (on base layer side). This asymmetric shape allows the insulating layer to adequately cover the coil wiring formation area at the base layer while reducing material volume above the coil wiring, thereby increasing the volume available for the magnetic layer to improve inductance value.
2Volume of stationary object
If the insulating layer width is reduced to increase magnetic layer volume, then the inductance value can be improved, but the insulating layer may not adequately cover the coil wiring
Solution Approach 1:
The insulating layer exhibits local quality variation through its trapezoidal shape: it provides maximum width and coverage at the base layer side where the coil wiring formation area requires insulation, and gradually reduces width toward the top where less coverage is needed. This localized adaptation of the insulating layer dimensions optimizes both coverage reliability and magnetic layer volume.
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 configuration enhances the inductance value of the inductor component by optimizing the shape of the insulating layer to accommodate a larger magnetic layer volume, thereby improving the inductance performance.
Implementation Method 1
forming an insulating layer by disposing a positive-type photosensitive insulating material on the main surface of the base layer so as to cover the coil wiring; and removing a range of the insulating layer other than a portion covering the coil wiring by photolithography
Data Source
AI summary
An inductor component capable of improving an inductance value and a method for manufacturing the same. An inductor component includes a base layer having a main surface; a coil wiring formed on the main surface of the base layer; an insulating layer covering the coil wiring; and a magnetic layer covering the insulating layer. A shape of the insulating layer in a section perpendicular to the main surface of the base layer is a trapezoidal shape in which a width of a first end surface on a side opposite to the base layer is narrower than a width of a second end surface on the base layer side, and the width of the first end surface is narrower than a width of a formation area of the coil wiring in a direction parallel to the main surface of the base layer.