Multilayer Coil Insertion Prevents Short Circuit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional multilayer electronic components face issues with short circuits due to blurring or misplacement during the printing of coil conductors, leading to a reduced number of turns in the coil and undesirable characteristics.
Innovation Solution
A multilayer coil design that includes a laminate body with insulating layers and a linear coil conductor, featuring insertions between the closest parts of the coil conductor to prevent short circuits, along with a manufacturing method that forms these insertions before the coil conductors to maintain the coil's structure and prevent magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance between pad portions is increased to prevent short circuits caused by blurring and misplacement during printing, then manufacturing reliability is improved, but the length of the coil conductor is reduced and the number of turns of the coil is decreased
Solution Approach 1:
The coil conductor is divided into multiple separate printed portions (first through fourth portions) that are positioned at different locations on the insulating layer. These segmented portions are subsequently connected through via-hole conductors to form a complete multi-turn coil, allowing each portion to be printed independently with adequate spacing while achieving the desired number of turns.
Solution Approach 2:
The coil structure transitions from a planar two-dimensional layout to a three-dimensional multi-layer structure. Coil conductors are printed on multiple insulating layers stacked in the thickness direction, and via-hole conductors connect corresponding portions across layers, enabling the coil to achieve adequate turns while maintaining printing precision on each layer.
2Manufacturing precision
If the distance between pad portions is increased to prevent short circuits, then manufacturing precision is improved, but the length of the coil conductor is shortened
Solution Approach 1:
Multiple coil conductor portions are nested across different insulating layers, with each layer containing a portion of the overall coil structure. Via-hole conductors penetrate through the insulating layers to connect these nested portions, effectively distributing the total conductor length across multiple compact layers rather than requiring a single long planar trace.
3Productivity
If via-hole conductors are used to connect coil conductors across layers, then device complexity is increased, but the coil can achieve desired characteristics with adequate number of turns
Solution Approach 1:
The via-hole conductors serve multiple functions: they electrically connect coil conductor portions across different insulating layers, provide mechanical support for the multi-layer structure, and enable the formation of continuous multi-turn coils in a compact three-dimensional arrangement. This multi-functionality justifies the additional structural elements.
Data Source
AI summary
A multilayer coil having a laminate body having a plurality of insulating layers including a specified insulating layer. A linear coil conductor is substantially looped on the specified insulating layer. An insertion is located on the specified insulating layer, in a position between a first part and a second part of the coil conductor. The first part and the second part are closest parts to each other in the coil conductor. Along a boundary surface between the first part of the coil conductor and the insertion, the first part is located at an upper side of the coil conductor with respect to a stacking direction.