Inductor With Insulating Wall Guides For Uniform Coil Patterns
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Solution Overview
Problem
Existing power inductor manufacturing processes face limitations in forming coils with uniform high aspect ratios due to challenges in thickness uniformity and direct current resistance distribution.
Innovation Solution
The inductor design includes a body with a support member, coil patterns, and single integrated insulating walls that guide the growth of coil patterns, ensuring uniform thickness and aspect ratio, and a double insulating structure to secure insulation and prevent short circuits, using a combination of isotropic and anisotropic plating methods to control plating layers and reduce direct current resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used to form coils, then production is simpler, but uniform high aspect ratios cannot be achieved
Solution Approach 1:
The patent applies preliminary action by pre-forming insulating walls with specific aspect ratios before coil deposition. These insulating walls serve as templates that guide the coil formation process, ensuring uniform high aspect ratios are achieved without complex manufacturing steps. The insulating walls are formed first, then coils are deposited around them, eliminating the need for complex direct coil formation processes.
Solution Approach 2:
The patent uses insulating walls as intermediary structures that facilitate coil formation. These walls act as mediators between the manufacturing process and the final coil structure, providing a simple pathway to achieve uniform high aspect ratios. The insulating walls are easier to form with uniform dimensions than coils directly, and they subsequently guide the coil deposition process to achieve the desired geometry.
2Manufacturing precision
If coil thickness varies, then manufacturing is easier, but direct current resistance distribution deteriorates
Solution Approach 1:
The patent applies preliminary action by forming insulating walls with controlled thickness before coil deposition. These insulating walls serve as thickness references that ensure uniform coil thickness during the deposition process. By establishing the thickness standard in advance through the insulating walls, the coil thickness uniformity is maintained, which directly improves direct current resistance distribution.
3Reliability
If multiple insulating structures are used, then insulation reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining the insulating wall and coil structure into an integrated formation process. The insulating walls and coils are formed simultaneously or in a tightly integrated sequence, reducing the number of separate manufacturing steps. This integration maintains insulation reliability while simplifying the overall manufacturing process by eliminating the need for multiple separate insulating structure additions.
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 achieves a high aspect ratio for the coil patterns while improving direct current resistance distribution and insulation reliability, eliminating the need for additional processing steps and enhancing economical efficiency.
Implementation Method 1
using a combination of isotropic and anisotropic plating methods to control plating layers
Data Source
AI summary
An inductor includes a coil having a plurality of coil patterns and external electrodes connected thereto. An innermost coil pattern and an outermost coil pattern in the coil grow using first and second insulating wall as growth guides and the inductor has a structure in which there is no deviation in thickness and shape between the coil patterns.