Single-Layer Coil Structure for Higher Inductance in Thin PCB Mounts
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Solution Overview
Problem
There is a need for a coil component that enhances inductance characteristics by increasing the central core area and effective volume while reducing overall thickness, and also minimizes the risk of short circuits when mounted on a PCB board.
Innovation Solution
A single-layer coil structure with a support member and external electrodes exposed only to the lower surface, featuring a coil portion with a specific aspect ratio and lead-out portions connected via vias, which increases the central core area and effective volume, and reduces the risk of short circuits by preventing contact between the external electrodes and the coil portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single-layer coil structure is applied, then the central core area and effective volume are increased, but the overall thickness must be reduced
Solution Approach 1:
The patent transitions from a multi-layer vertical stacking approach to a single-layer planar expansion approach. The coil structure is designed with an aspect ratio greater than 0.04 and less than or equal to 15, allowing the coil to occupy more area in the horizontal plane while maintaining reduced thickness in the vertical direction. This dimensional shift resolves the contradiction by increasing effective volume through lateral expansion rather than vertical stacking.
2Reliability
If external electrodes are exposed only to the lower surface, then the risk of short circuit is reduced, but the integration complexity increases
Solution Approach 1:
The patent extracts the external electrodes from the upper surface and positions them exclusively on the lower surface of the coil component. This separation removes the potential for short circuits between electrodes and the coil portion, as the electrodes no longer occupy the same spatial region. The lead-out portions extend through the coil structure to connect the external electrodes to the coil, maintaining electrical functionality while improving safety.
3Reliability
If the coil portion aspect ratio is optimized between 0.04 and 15, then the inductance characteristics are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a precise aspect ratio range for the coil portion (greater than 0.04 and less than or equal to 15) to optimize inductance characteristics. This parameter control ensures that the coil geometry produces the desired electromagnetic properties. The single-layer structure with defined dimensions allows for controlled inductance values while maintaining manufacturability within the specified tolerances.
Data Source
AI summary
A coil component includes a body having a first surface and a second surface opposing each other in a first direction and respectively having a recess formed therein, and a third surface and a fourth surface connecting the first surface and the second surface and opposing each other in a second direction, a coil including a coil portion disposed within the body and having a plurality of turns, a first lead-out portion disposed within the body and extending to the recess of the first surface of the body, and a second lead-out portion having at least a portion extending from an outermost turn of the coil portion to the recess of the second surface of the body, and first and second external electrodes disposed on the third surface of the body and extending to the recess to be connected to the first and second lead-out portions, respectively.