Laminated Inductor Through-Conductor Layout for Lower DC Resistance
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Solution Overview
Problem
Existing laminated inductors face challenges in optimizing the electrical characteristics of inductance value and DC resistance while maintaining reliable connections, particularly due to the limitations in the shape and size of the through conductor.
Innovation Solution
The laminated inductor features a triangular-shaped through conductor whose two sides align with the outer edge of the element body in plan view, effectively utilizing the space between the element body and the composite coil to increase the connection area and reduce DC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the diameter of the circular lead conductor is increased, then the DC resistance decreases, but the volume of the base part decreases and the inductance value decreases
Solution Approach 1:
The patent changes the lead conductor shape from a symmetric circular form to an asymmetric triangular shape with two sides along the outer edge of the element body. This asymmetric configuration allows the conductor to extend closer to the external electrodes while maintaining adequate spacing from the composite coil, thereby reducing DC resistance without compromising the base part volume or inductance value.
Solution Approach 2:
The lead conductor is designed with different geometric characteristics in different regions: two sides follow the outer edge of the element body to maximize connection area with external electrodes, while the third side maintains appropriate distance from the composite coil. This localized optimization of conductor geometry resolves the contradiction between minimizing resistance and preserving inductance.
2Volume of stationary object
If the diameter of the lead conductor is reduced, then the inductance value is improved, but the resistance of the lead conductor and connection resistance are increased
Solution Approach 1:
The asymmetric triangular shape with two sides along the element body edge enables the conductor to achieve sufficient connection area with external electrodes despite having a smaller overall footprint. This configuration maintains reliable electrical connections while preserving the base part volume and inductance value.
Solution Approach 2:
The lead conductor utilizes the vertical dimension by extending in the lamination direction from the external electrodes through the element body to connect with the composite coil. This three-dimensional configuration allows adequate connection area without requiring a large planar diameter, thus maintaining both connection reliability and inductance value.
3Volume of stationary object
If the diameter of the lead conductor is small, then the inductance value is improved, but the connection area between the lead conductor and the external electrode is reduced
Solution Approach 1:
The triangular configuration with two sides along the element body edge maximizes the connection area with external electrodes at the corners, where the conductor can spread out along the edges. This asymmetric design achieves adequate connection area without requiring a large circular diameter, thus preserving the base part volume and inductance value.
Data Source
AI summary
A laminated inductor having improved electrical characteristics by optimizing the shape of a through conductor in plan view. A laminated inductor includes an element body having magnetic layers laminated therein and having a hexahedron shape; external electrodes at at least each of four corners of a bottom surface of the element body; a composite coil including a first coil in which conductor layers in the element body are connected in a lamination direction and which has a winding axis in the lamination direction, and a second coil which is above the first coil in the lamination direction, in which conductor layers in the element body are connected in the lamination direction, and which has a winding axis in the lamination direction; and through conductors extending in the lamination direction from on the external electrodes and connected to both ends of the first and second coils.