Laminated Inductor Structure for Electrostatic Breakdown Prevention
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Solution Overview
Problem
Conventional inductor components face challenges in enhancing inductance acquisition efficiency while maintaining adequate insulation, as increasing metal magnetic powder content to improve magnetic permeability reduces insulation, leading to potential dielectric breakdown and manufacturing inefficiencies.
Innovation Solution
The inductor component incorporates a laminated structure with a first and second magnetic layer containing metal magnetic powder, along with a spiral wiring and vertical wiring configuration. A lead-out part exposed from the side surface provides a discharge path for static electricity, preventing dielectric breakdown and eliminating the need for dedicated static protection lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation of magnetic layers is reduced to enhance inductance acquisition efficiency, then the magnetic permeability is improved, but dielectric breakdown may occur due to static electricity
Solution Approach 1:
The patent introduces a resin layer as an intermediary insulating material between the magnetic layers and around the spiral conductor. This resin layer acts as a mediator that provides adequate insulation to prevent dielectric breakdown from static electricity, while allowing the magnetic layers to maintain high metal magnetic powder content for enhanced inductance acquisition efficiency.
2Reliability
If a dedicated line with static electricity countermeasures is constructed to prevent dielectric breakdown, then the insulation reliability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent makes the inductor component itself self-protecting against static electricity by incorporating the resin layer insulation structure directly into the component design. The component's own structure provides the necessary insulation and static electricity resistance, eliminating the need for external dedicated manufacturing lines with special static electricity countermeasures, thereby reducing manufacturing complexity.
3Reliability
If the metal magnetic powder content is increased to improve inductance acquisition efficiency, then the magnetic performance is enhanced, but the manufacturability is reduced due to static electricity sensitivity
Solution Approach 1:
The patent incorporates the resin layer insulation structure in advance during the manufacturing process, before the components are subjected to static electricity during production. This beforehand cushioning approach allows the use of high metal magnetic powder content for enhanced inductance acquisition efficiency while the pre-built insulation structure protects against static electricity damage, thereby maintaining manufacturability.
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 ensures effective discharge of static electricity, reducing the risk of dielectric breakdown and maintaining high inductance acquisition efficiency without the need for additional static protection measures, thus enhancing manufacturability.
Implementation Method 1
a discharge path for static electricity can be ensured with the lead-out part exposed from the side surface of the element body. For example, by connecting the lead-out part to a ground line in a manufacturing process, static electricity flows out to the ground line
Implementation Method 2
an element body including a first magnetic layer and a second magnetic layer that contain a metal magnetic powder
Data Source
AI summary
An inductor component comprising an element body including a first and second magnetic layers that contain a metal magnetic powder and that are laminated along a first direction, a spiral wiring disposed between the first and second magnetic layers, a vertical wiring connected to the spiral wiring and extending in the first direction to penetrate the element body and an external terminal connected to the vertical wiring and exposed on a first principal surface of the element body orthogonal to the first direction. The spiral wiring is disposed on a first plane orthogonal to the first direction and includes a pad part to which the vertical wiring is connected, a spiral part extending from the pad part on the first plane, and a lead-out part extending from the pad part on the first plane and exposed from a side surface of the element body parallel to the first direction.