Laminated Coil Parallel Lead-Out Structure for High-Current Reliability

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Solution Overview

Problem

Existing laminated coil components face issues with heat generation and electrochemical migration in lead-out conductors when high currents are passed, leading to potential disconnection and loss of functionality.

Innovation Solution

A laminated coil component design where multiple coil conductors are connected in parallel via via conductors penetrating insulating layers, with dual lead-out conductors connecting the coil to the outer electrode, reducing current density and preventing heat generation and electrochemical migration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple coil conductors are connected in parallel to reduce DC resistance and enable large current passage, then the coil's current handling capability is improved, but the lead-out conductor experiences increased heat generation and electrochemical migration

Engineering Contradiction:

Improvecurrent handling capabilityVSAvoidheat generation and electrochemical migration in lead-out conductor

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent divides the single lead-out conductor into multiple separate lead-out conductors (first lead-out conductor and second lead-out conductor). Each lead-out conductor connects to a different terminal of the outer electrode, distributing the current path. This segmentation reduces the current density in each individual lead-out conductor, thereby reducing heat generation and electrochemical migration while maintaining the overall high current handling capability of the coil component.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If a single lead-out conductor is used to connect the coil to the outer electrode, then the device structure is simplified, but the reliability decreases due to potential disconnection from heat generation and electrochemical migration

Engineering Contradiction:

Improvelead-out conductor configurationVSAvoidfunctional continuity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent implements redundancy by providing multiple lead-out conductors that connect the coil to different terminals of the outer electrode. This creates alternative current paths in advance, cushioning against the risk of disconnection. If one lead-out conductor fails due to heat generation or electrochemical migration, the current can still flow through the other lead-out conductors, maintaining the functional continuity and reliability of the coil component.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 design effectively reduces the likelihood of heat generation and electrochemical migration in lead-out conductors, maintaining functionality even when high currents are passed, and ensures continued operation by providing redundant current paths.

Implementation Method 1

a via conductor that penetrates the insulating layers in the laminating direction... The first parallel sections are connected in parallel by the via conductor

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

reducing current density and preventing heat generation and electrochemical migration... The outermost coil conductor is electrically connected to the same outer electrode by a first lead-out conductor at one end of the first parallel section and by a second lead-out conductor at the other end

Methodology Applied

Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS20230317353A1Laminated coil component

Publication Date: 2023.10.05 MURATA MFG CO LTD

AI summary

A laminated coil component including a body in which insulating layers are laminated in a laminating direction; a coil in the body; and an outer electrode on a surface of the body and electrically connected to the coil. The coil includes coil conductors laminated in the laminating direction that are electrically connected by a via conductor that penetrates the insulating layers in the laminating direction. The coil conductors include a first laminated part including adjacent coil conductors including an outermost coil conductor at an outermost position in the laminating direction. The first laminated part has first parallel sections in which all of the coil conductors of the first laminated part overlap each other when viewed in the laminating direction. The first parallel sections are connected in parallel by the via conductor, and the outermost coil conductor is electrically connected to the same outer electrode by first and second lead-out conductors.