Thin Coil Electronic Component With 3D Connection Electrode
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Solution Overview
Problem
There is a growing demand for thin power inductors to slim down products and increase component arrangement flexibility, while also requiring low loss and high efficiency to extend battery life in mobile devices.
Innovation Solution
A coil electronic component with a thin thickness is developed, comprising a magnetic body with a support member and coils, an external electrode on the magnetic body, and a connection electrode within the magnetic body connecting the coil to the external electrode. The connection electrode has an extension portion with a greater diameter than the remaining portion, and the coils include a first and second coil pattern connected by a via.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the thickness of the power inductor is reduced to slim down products, then the degree of freedom in component arrangement increases, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The connection electrode transitions from a planar structure to a three-dimensional structure with an extension portion protruding in the thickness direction. This dimensional change allows the electrode to connect coils on opposite surfaces without requiring complex lateral routing, thereby reducing in-plane complexity while achieving thin overall thickness.
Solution Approach 2:
The extension portion of the connection electrode is embedded within the magnetic body, with the magnetic body enclosing the coil and connection electrode structures. This nesting arrangement integrates multiple components into a compact thin-profile package, reducing overall thickness while maintaining functional integrity.
2Length of stationary object
If the thickness of the power inductor is reduced to slim down products, then the product profile becomes thinner, but the manufacturing precision requirements increase
Solution Approach 1:
The connection electrode is divided into distinct portions: a main body portion and an extension portion protruding in the thickness direction. This segmentation allows each portion to be formed and positioned independently, simplifying the manufacturing process and reducing precision requirements compared to forming a single complex structure.
Solution Approach 2:
The extension portion is formed to protrude in the thickness direction before final assembly, establishing predetermined connection positions between coils. This preliminary positioning reduces the need for complex alignment procedures during assembly, thereby lowering manufacturing precision requirements.
Data Source
AI summary
A coil electronic component may include a magnetic body having a first surface and a second surface opposing each other in a first direction, a third surface and a fourth surface opposing each other in a second direction intersecting the first direction, and a fifth surface and a sixth surface opposing each other in a third direction intersecting both the first and second directions and including a magnetic material, a coil embedded in the magnetic body, an external electrode disposed on the sixth surface of the magnetic body, and at least one connection electrode disposed within the magnetic body and connecting the coil and the external electrode and including an extension portion having a diameter greater than a diameter of a remaining portion of the connection electrode.