Laminated Circuit Board Built-In Inductor Design
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Solution Overview
Problem
Conventional laminated circuit boards face difficulties in forming low-resistance electrode patterns on ferrite sheets, which are essential for efficient inductor formation.
Innovation Solution
A laminated circuit board design that includes a base with multiple metal layers, where each metal layer is patterned to form spiral winding parts and electrode parts, and these layers are laminated and bonded to create a built-in low-resistance inductor, with an insulating layer and magnetic body to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ferrite sheets with electrode patterns are used, then inductor formation is possible, but the resistance is high and manufacturing is difficult
Solution Approach 1:
The inductor structure is segmented into multiple metal layers (first metal layer with first electrode, second metal layer with second electrode) stacked vertically. Each layer can be manufactured independently with simpler electrode patterns, avoiding the complexity of forming low-resistance patterns on single ferrite sheets. The segmentation allows each layer to contribute to the overall inductance while maintaining manufacturability.
Solution Approach 2:
The invention transitions from planar electrode patterns to a three-dimensional stacked structure. Instead of forming complex low-resistance patterns on a two-dimensional ferrite sheet surface, the solution uses vertical stacking of multiple metal layers with electrodes extending in the thickness direction. This dimensional change enables lower resistance by increasing the effective conductor cross-section while maintaining simpler manufacturing processes for each layer.
2Reliability
If ferrite sheets are laminated to form inductors, then inductor function is achieved, but resistance remains high
Solution Approach 1:
The invention uses composite material structures where metal layers (such as copper or aluminum) are combined with ferrite or ceramic bases. The metal layers provide low-resistance current paths, while the ferrite/ceramic provides magnetic properties and structural support. This composite approach reduces overall resistance compared to using ferrite sheets alone, while maintaining inductor functionality.
Solution Approach 2:
The invention merges multiple metal layers with electrodes into a single integrated inductor structure. The first metal layer and second metal layer are electrically connected through via electrodes, creating a unified low-resistance current path. This merging of multiple conductive elements reduces overall resistance compared to conventional single-layer ferrite sheet inductors.
3Reliability
If complex electrode patterns are formed on ferrite sheets, then inductor functionality is achieved, but manufacturing complexity increases
Solution Approach 1:
The complex inductor structure is segmented into multiple simpler metal layers. Each layer contains simpler electrode patterns that are easier to manufacture, rather than attempting to form complex patterns on a single ferrite sheet. The segmentation distributes the manufacturing complexity across multiple identical or similar layers, simplifying the overall fabrication process.
Solution Approach 2:
The invention uses repeated copying of the metal layer structure. Multiple identical or similar metal layers with the same electrode patterns are stacked and connected. This copying approach simplifies manufacturing by using the same template or mold for each layer, reducing the complexity of creating unique complex patterns while achieving the desired inductor functionality through repetition.
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
The solution enables the easy formation of a built-in low-resistance inductor with improved electrical connectivity and reduced resistance, suitable for use in electronic components such as DC-DC converters.
Implementation Method 1
the first electrode and the second electrode are bonded and electrically connected to each other
Data Source
AI summary
A laminated circuit board includes a base having a first surface, and a second surface on an opposite side from the first surface, a first metal layer provided in the base and including a first electrode exposed from the first surface, and a second metal layer provided in the base and including a second electrode exposed from the second surface. The first metal layer includes an inductor electrically connected to the first electrode, and the first electrode and the second electrode are bonded and electrically connected to each other.