Surface-Mounted Inductor Terminal Layout for Lower DC Resistance
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Solution Overview
Problem
The direct-current resistance of surface-mounted inductors increases with the length of the coil conductor between the wound section and the extended sections, affecting their performance.
Innovation Solution
A surface-mounted inductor design with a base body of a substantially rectangular-parallelepiped shape, featuring a coil conductor embedded in a core with extended sections that connect to outer electrodes, where the transition portions are angled to reduce the length between the wound section and the exposed portions, thereby minimizing direct-current resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil conductor is extended from the wound section to the base body surface, then the inductor can be connected to external terminals, but the direct-current resistance increases due to the length of the conductive wire
Solution Approach 1:
The patent utilizes the thickness direction (vertical dimension) of the base body to create a more direct path for the conductive wire. By having the extended section extend in the thickness direction from the wound section to the exposed surface, the wire travels a shorter distance compared to extending along the length or width directions, thereby reducing direct-current resistance while maintaining connection capability
Solution Approach 2:
The patent employs a curved transition portion that smoothly connects the wound section to the extended section. This curved path optimizes the wire routing by reducing sharp bends and minimizing the overall length of the conductive path, thereby reducing resistance while maintaining the necessary geometric transition from the compact wound section to the exposed terminal area
2Reliability
If the transition portion is made long to ensure proper connection, then the connection reliability improves, but the direct-current resistance increases
Solution Approach 1:
The patent resolves this contradiction by utilizing the thickness direction of the base body to create a more direct spatial path. The extended section of the conductive wire extends vertically from the wound section through the core to the exposed surface, significantly shortening the wire length compared to horizontal routing while maintaining adequate transition and connection reliability
Data Source
AI summary
An inductor includes a base body including a coil conductor and a core in which the coil conductor is embedded. The coil conductor includes a wound section in which a conductive wire is wound. The base body is substantially rectangular-parallelepiped-shaped and includes a pair of principal faces that are opposite to each other, a pair of side faces that are opposite to each other and adjacent to the principal faces, and two end faces that are opposite to each other and adjacent to the principal and side faces. Two extended sections extend from respective ones of two extending points on an outer periphery of the wound section. The two extended sections include respective transition portions and respective exposed portions, the transition portions connect the extending points to exposed points exposed on the two end faces of the base body, and the exposed portions are exposed on the end faces.