Integrated Inductor Component with Helical Coil Structure
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Solution Overview
Problem
The existing inductor components, particularly those with a single inductor configuration, fail to provide satisfactory characteristics for complex electronic devices, leading to variations in inductor characteristics when multiple inductors are required, which can result in suboptimal performance in electronic devices.
Innovation Solution
The inductor component is designed with a core member having multiple metal plates and metal pins forming a helical coil, allowing for the integration of multiple inductors with reduced characteristic variation, and is configured to improve mountability and reduce direct current resistance (DCR) by using columnar terminal electrodes and strategically positioning the core members and metal pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate inductor components are used to meet the requirements of electronic devices, then the required inductance values can be achieved, but characteristic variation among inductors increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple inductors into a single integrated inductor component. The core member includes multiple core portions with coils wound around them, all integrated within one component structure. This merging approach reduces characteristic variation among inductors while maintaining the required inductance values, eliminating the need to assemble multiple separate inductor components.
Solution Approach 2:
The inductor component is segmented into multiple independent inductor units, each consisting of a core portion and its associated coil. Each inductor unit can be independently designed to achieve specific inductance values, while the overall integration within one component maintains consistency and reduces variation. The segmentation allows for flexible configuration to meet different electronic device requirements.
2Reliability
If traditional inductor configurations are used, then manufacturing processes are simpler, but the inductor characteristics do not meet the requirements of sophisticated electronic devices
Solution Approach 1:
Multiple inductors are merged into a single integrated component with a unified manufacturing process. The core member is formed as one piece with multiple core portions, and coils are wound around these core portions in an integrated manner. This approach achieves sophisticated inductor characteristics required by modern electronic devices while maintaining manufacturing efficiency through consolidation rather than assembly of multiple separate components.
3Manufacturing precision
If inductors are integrated into a single component, then characteristic variation is reduced, but the device structure becomes more complex
Solution Approach 1:
The integrated inductor component is segmented into distinct inductor units, each with its own core portion and coil. This segmentation allows for precise control of each inductor's characteristics while maintaining integration within one component. The modular segmented structure reduces characteristic variation and improves manufacturing precision without creating excessive structural complexity, as each segment follows a standardized design pattern.
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 inductor characteristics, reduces variation among inductors, and improves the overall performance of the inductor component, enabling better inductance values and reduced DCR, thus addressing the limitations of single inductor configurations.
Implementation Method 1
The coil includes a plurality of first metal plates, which are spaced apart from each other and disposed on the upper surface of the core member, a plurality of second metal plates, which are spaced apart from each other and disposed on the lower surface of the core member, and a plurality of metal pins. The coil is formed into a helical shape by connecting the plurality of first metal plates to the plurality of second metal plates, with the plurality of metal pins therebetween.
Data Source
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AI summary
An inductor component (10) includes core members (41 and 42), a coil disposed in the core members, and terminal electrodes (61 to 63). The coil includes first metal plates (21 to 24) disposed on an upper surface of the core members (41 and 42), second metal plates (31 to 35) disposed on a lower surface of the core members (41 and 42), and a plurality of metal pins (511, 521, 522, 531, 532, 541, 542, and 552) each passing through one of the core members (41 and 42) in a thickness direction. The coil is formed into a helical shape by connecting the first metal plates (21 to 24) to the second metal plates (31 to 35), with the plurality of metal pins (511, 521, 522, 531, 532, 541, 542, and 552) therebetween. The terminal electrodes (61 to 63) are spaced apart along a direction in which the helical shape extends, and are connected to the coil.