Laminated Inductor C-Shaped Coil Stacking for High Q-Value
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Solution Overview
Problem
Conventional laminated inductors face challenges in achieving high Q-value while maintaining high inductance as they become smaller, due to reduced core area and increased resistance, leading to inefficient magnetic flux and lower inductance.
Innovation Solution
The laminated inductor design features a spiral coil conductor with C-shaped and line-shaped patterns on insulator layers, where C-shaped patterns dominate the core area and are stacked in parallel, connected by via hole conductors, to enhance inductance and reduce resistance, thereby achieving high Q-value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the laminated inductor is made smaller, then the device size is reduced, but the core area decreases and inductance drops
Solution Approach 1:
The patent transitions from planar conductor patterns to three-dimensional stacked C-shaped patterns connected by via holes. This vertical stacking in the thickness direction enables the coil to utilize the third dimension, effectively increasing the core area and inductance without increasing the planar footprint, thus resolving the contradiction between miniaturization and maintaining core area.
Solution Approach 2:
Multiple C-shaped conductor patterns are nested vertically within the laminate thickness, with each pattern stacked on top of another and connected through via holes. This nesting approach allows the coil to occupy multiple layers within the same planar space, effectively increasing the core area and inductance while maintaining a compact size.
2Ease of manufacture
If conventional conductor patterns are used, then manufacturing is simpler, but magnetic flux does not pass through effectively and Q-value drops
Solution Approach 1:
The conductor pattern is segmented into multiple C-shaped sections stacked vertically, with each section contributing to the magnetic flux path. The via holes segment the electrical connection across layers, creating multiple parallel flux paths that improve magnetic efficiency and Q-value while maintaining manufacturability through standard lamination and via-hole formation processes.
Solution Approach 2:
The patent employs a composite structure combining conductor patterns, insulator layers, and via hole conductors to create an optimized magnetic flux path. This composite laminate structure enhances magnetic flux penetration and reduces energy loss, improving Q-value while remaining compatible with conventional manufacturing techniques.
3Loss of energy
If coil wires are arranged in parallel, then direct-current resistance increases, but high Q-value can be achieved
Solution Approach 1:
The patent resolves the resistance-Qvalue contradiction by moving from parallel wire arrangement to a vertical stacked configuration. The C-shaped patterns connected via via holes create multiple parallel current paths in the vertical dimension, reducing the effective resistance while maintaining the Q-value benefits of the stacked geometry. This three-dimensional current distribution simultaneously addresses both resistance and Q-value requirements.
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 design effectively increases the core area and reduces coil length, resulting in higher inductance and improved Q-value by minimizing resistance, making it suitable for smaller electronic devices with multiple bandwidth support.
Implementation Method 1
via hole conductors that penetrate through the insulator layers and electrically connect the multiple conductor patterns
Implementation Method 2
a coil conductor formed in a spiral shape inside the laminate
Data Source
AI summary
A laminated inductor includes: a laminate constituted by multiple insulator layers; external electrodes formed on the outside of the laminate; and a coil conductor formed spirally inside the laminate, wherein the coil conductor has leaders that electrically connect to the external electrodes and a coil body other than the leaders, wherein the coil conductor has conductive patterns formed on the insulator layers, and via hole conductors that penetrate through the insulator layers and electrically connect the multiple conductor patterns, wherein all of the conductor patterns constituting the coil body are either a C-shaped pattern or line-shaped pattern, wherein the coil body has a partial structure where two or more C-shaped pattern layers are stacked together successively, and wherein the number of C-shaped patterns in the coil body is greater than that of line-shaped patterns.