Multilayer Inductor Electrode Curvature for Stable Magnetic Path
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Solution Overview
Problem
Multilayer inductors face challenges with sharp coil cross-section edges leading to reduced magnetic path areas, alignment tolerance issues, and variations in frequency characteristics and inductance due to parasitic capacitance.
Innovation Solution
A multilayer inductor design featuring internal electrodes with tapered shapes and side surface cover layers, where the electrodes have specific thickness ratios and are made of materials that match or differ from the main body, to create a flat surface and maintain magnetic path integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If metal patterns are printed on sheets to form coils, then the inductor can be manufactured with low profile, but the coil cross-section develops sharp edges that reduce magnetic path area
Solution Approach 1:
The internal electrodes are designed with rounded corners instead of sharp edges, creating a curved cross-sectional shape. This curvature eliminates the sharp edges that would otherwise reduce the magnetic path area, while maintaining the low-profile characteristic of the printed multilayer structure.
2Ease of manufacture
If metal patterns are printed on sheets to form coils, then manufacturing is simplified, but alignment tolerance between layers deteriorates due to sharp edges
Solution Approach 1:
Rounded corners on internal electrodes provide a more tolerant geometric feature for alignment between stacked layers. The curved shape reduces sensitivity to positional deviations compared to sharp corners, improving alignment tolerance while maintaining the simplicity of the printing manufacturing process.
3Productivity
If sharp-edged coils are formed by printing, then parasitic capacitance increases, but this leads to frequency characteristic deterioration and inductance variation
Solution Approach 1:
The rounded corner design of internal electrodes reduces the concentration of electric field lines at sharp edges, thereby reducing parasitic capacitance. This maintains the efficient printed coil formation process while improving frequency characteristic stability and reducing inductance variation.
Data Source
AI summary
A multilayer inductor may include: a main body that has a first surface and a second surface facing each other in a first direction, a third surface and a fourth surface connecting the first surface and the second surface and facing each other in a second direction, and including a magnetic material; a plurality of internal electrodes disposed inside the main body; and side surface cover layers that respectively covers the third surface and the fourth surface of the main body. At least one internal electrode of the plurality of internal electrodes may include a first electrode surface and a second electrode surface facing each other in the third direction and a third electrode surface connecting the first electrode surface and the second electrode surface and parallel to the third surface, the fourth surface, or both, and the third electrode surface may contact the side surface cover layer.