Multilayer Coil Width Variation in Parallel Layers to Limit Stress
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Solution Overview
Problem
In multilayer coil components, the difference in shrinkage between coil conductors and insulating layers leads to internal stress concentration, potentially causing cracks and reducing the overall strength of the component, especially when multiple coil conductors are laminated and connected in parallel.
Innovation Solution
The multilayer coil component incorporates coil conductors with different widths in the parallel connection portions, which reduces stress concentration by shifting the edges of the conductors, thereby minimizing internal stress and the occurrence of defects like cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple coil conductors are laminated and connected in parallel to each other by via conductors, then the current carrying capacity is increased, but the internal stress concentration in the insulating layer increases due to the large volume of overlapping via conductors
Solution Approach 1:
The patent applies local quality by making the conductor widths of laminated coil conductors non-uniform. Specifically, in regions where multiple coil conductors are stacked, at least one conductor has a different width from the others, creating local variations in the conductor structure. This local differentiation reduces stress concentration at the interfaces between conductors and insulating layers, while still maintaining the overall parallel connection structure for high current capacity.
2Reliability
If the internal stress exceeds the fracture toughness of the insulating layer, then defects such as cracks occur in the multilayer body, but maintaining uniform conductor widths simplifies the manufacturing process
Solution Approach 1:
The patent implements local quality by introducing width variations only in specific regions where conductors are laminated, while other portions of the conductors maintain uniform widths. This selective approach reduces manufacturing complexity compared to completely non-uniform conductors, while still effectively reducing stress concentration and preventing cracks in the insulating layer.
Solution Approach 2:
The patent applies parameter changes by modifying the width parameter of coil conductors in specific regions. By changing the conductor width from uniform to non-uniform in laminated regions, the stress distribution is altered to prevent crack formation. This parameter modification is implemented in a controlled manner to balance reliability improvement with manufacturing feasibility.
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 effectively reduces internal stress in the multilayer body, enhancing the strength and reliability of the multilayer coil component by controlling stress within a specific range through adjustable conductor width ratios.
Implementation Method 1
the difference in degree of shrinkage between the coil conductors and the insulating layer tends to cause stress to concentrate in the insulating layer between coil conductors
Data Source
AI summary
A multilayer coil component includes a multilayer body in which multiple insulating layers are laminated in a lamination direction and a coil is formed inside. The multilayer coil component also includes outer electrodes formed on respective surfaces of the multilayer body and electrically connected to the coil. The coil is formed of multiple coil conductors that are laminated together with the insulating layers in the lamination direction and are electrically connected to each other. The coil includes a parallel connection portion formed of two layers or more of the coil conductors that are electrically connected in parallel to each other by via conductors. The coil conductors laminated in the parallel connection portion have different conductor widths.