Laminated Inductor With Internal Lead Via Conductor
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Solution Overview
Problem
Laminated inductors with external electrodes on the bottom surface have a small electrode area, poor inductance efficiency, and unreliable DC-superposed characteristics due to exposed internal electrodes and lead conductors formed outside the coil.
Innovation Solution
A laminated inductor design with coiled electrodes and lead via conductors inside the laminate, where the coiled electrodes are connected internally, and external electrodes are formed on the bottom surface, allowing for a larger electrode area and improved inductance efficiency by avoiding magnetic flux through the lead via area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If lead conductors are formed outside the coil on the bottom surface, then the inductor structure is simplified, but the electrode area becomes small and inductance efficiency deteriorates
Solution Approach 1:
The patent transitions from forming lead conductors on the two-dimensional bottom surface to extending coiled electrodes through the third dimension (stacking direction) of the laminate. Multiple coiled electrodes are stacked in the thickness direction and connected via via conductors, effectively utilizing the vertical dimension to increase the total electrode area while maintaining a compact footprint.
Solution Approach 2:
The patent implements a nested structure where via conductors are embedded within the laminate layers to connect stacked coiled electrodes. The lead via conductor is positioned inside the area enclosed by the coiled electrodes, creating a nested arrangement that maximizes space utilization and increases effective electrode area without expanding the external dimensions.
2Ease of manufacture
If lead conductors are formed outside the coil, then manufacturing is easier, but magnetic flux saturation occurs and DC-superposed characteristics deteriorate
Solution Approach 1:
The patent extracts the lead via conductor from the magnetic flux path by positioning it inside the area enclosed by the coiled electrodes rather than allowing it to pass through the coil windings. This separation removes the source of magnetic flux saturation while maintaining electrical connectivity, thereby improving DC-superposed characteristics.
3Ease of operation
If internal electrodes are exposed to the outside, then connection to external circuits is achieved, but reliability deteriorates due to exposed ends
Solution Approach 1:
The patent merges the functions of internal electrode connection and external terminal formation by integrating the lead via conductor within the laminate structure. The via conductor connects stacked coiled electrodes internally while its top surface forms a flush terminal on the laminate surface, eliminating exposed electrode ends and improving reliability while maintaining electrical connectivity.
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 enhances inductance efficiency and DC-superposed characteristics by providing a larger electrode area and preventing magnetic flux saturation, resulting in a more reliable and efficient laminated inductor.
Implementation Method 1
a laminated inductor includes a coil formed of coiled electrodes each coiled up in one turn
Implementation Method 2
a lead via conductor extends to the inside of the area from the second end of one of the coiled electrodes furthest away from the external first and second electrodes. The lead via connects the end of the coiled electrode to the first external electrode.
Data Source
AI summary
A laminated inductor includes a laminate having a plurality of insulating layers, a helical coil and first and second external electrodes on an underside of the laminate. The helical coil has coiled electrodes, each coiled up in one turn, and the first and second external electrodes are connected to respective, or corresponding, ends of the helical coil. Each of the coiled electrodes of the helical coil follow a path along the periphery of one of the insulating layers and include first end located in the path and second end located outside the path. The helical coil and the first external electrode are connected to each other by a lead via conductor formed in a space that is enclosed by parts of the coiled electrodes including the first and second ends.