Inductor Interconnect Hole Structure for Miniaturized Connections
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Solution Overview
Problem
The miniaturization of inductor members requires high machining accuracy to connect conductive members to interconnects due to reduced spacing between adjacent interconnects, posing a challenge in manufacturing.
Innovation Solution
A method involving the formation of first and second holes in a magnetic structure, followed by the creation of insulating and conductive protrusions within these holes, ensuring precise connection of conducting cores to interconnects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If inductor members are miniaturized to reduce size, then the inductor member size decreases, but the spacing between adjacent interconnects decreases requiring higher machining accuracy
Solution Approach 1:
The connection structure is divided into multiple components: a conductive member with a body portion and a protrusion portion, an insulating member with a first hole and second hole, and an interconnect. This segmentation allows each component to be manufactured separately with standard precision, then assembled to achieve the required connection accuracy in miniaturized inductors
Solution Approach 2:
The insulating member is prepared in advance with pre-formed first and second holes at specific positions and depths. The conductive member is also prepared with a protrusion portion before assembly. This preliminary preparation of holes and protrusions ensures that when assembled, the connection between conductive member and interconnect achieves high precision without requiring ultra-precise machining of the final assembly
2Volume of moving object
If spacing between adjacent interconnects is reduced for miniaturization, then the inductor member becomes smaller, but the difficulty of properly connecting conductive members to interconnects increases
Solution Approach 1:
The insulating member acts as an intermediary component between the conductive member and the interconnect. It provides precisely positioned holes that guide the conductive member's protrusion to the interconnect, facilitating accurate connection even when interconnect spacing is reduced for miniaturization
Solution Approach 2:
The protrusion portion of the conductive member is inserted into the second hole of the insulating member, which itself is positioned within the overall inductor structure. This nested arrangement of protrusion within hole within interconnect structure enables precise connection in compact spaces
Data Source
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AI summary
A method for manufacturing an inductor member includes manufacturing a magnetic structure including at least two interconnects each having a conducting core and an insulating film covering a peripheral surface of the conducting core and being disposed at different positions in a first direction, and a magnetic layer in which the at least two interconnects are embedded, forming at least two first holes by using a routing method or a drilling method, each of the at least two first holes being connected to a different one of the at least two interconnects, forming a first protrusion of insulating property inside each of the at least two first holes, forming a second hole penetrating the first protrusion, and forming a second protrusion of conductive property in the second hole, the second protrusion being connected to the conducting core of a corresponding one of the interconnects.