Thin Film Inductor Segmented Support Member
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Solution Overview
Problem
The miniaturization and thinning of thin film type inductors lead to deformation issues during manufacturing due to low rigidity of coils with fine line widths and high flowability of magnetic sheets, resulting in dicing defects and reliability concerns.
Innovation Solution
A thin film type inductor design featuring a support member with through holes and multiple via portions filled with conductive material, which enhances the structural integrity and contact area between external electrodes and coils, preventing deformation and improving electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a coil with fine line width and high aspect ratio is used to achieve miniaturization and high inductance, then the inductance and size requirements are met, but the coil rigidity decreases leading to deformation during manufacturing
Solution Approach 1:
The support member is divided into multiple segments (first support segment, second support segment, third support segment) that are positioned at different locations around the coil. This segmentation allows each segment to provide localized support where needed, preventing deformation while maintaining the overall compact structure. The segmented approach enables the support member to counteract bending forces at multiple points along the coil's length.
Solution Approach 2:
The support member is constructed as a composite structure combining a base material with additional reinforcing elements (protrusions or recesses). This composite design enhances the mechanical strength and rigidity of the support member without significantly increasing its volume, allowing it to effectively support the fine-line coil while maintaining miniaturization goals.
2Reliability
If a magnetic sheet with high filling factor is used to achieve high inductance, then the inductance requirement is met, but the magnetic sheet flowability increases causing deformation during compression and curing
Solution Approach 1:
The support member with its reinforced structure is installed before the compression and curing process. This preliminary structural reinforcement prevents the magnetic sheet from deforming during the subsequent compression and curing steps. The support member acts as a pre-established framework that maintains geometric stability throughout the manufacturing process.
Solution Approach 2:
The support member modifies the mechanical parameters of the body structure by introducing stiffening elements. These structural modifications change the overall rigidity and deformation resistance of the body, allowing the high filling factor magnetic sheet to maintain its position and shape during compression and curing without excessive flowability issues.
3Length of moving object
If the coil line width is reduced for miniaturization, then the inductor size decreases, but the coil degree of rigidity decreases causing dicing defects
Solution Approach 1:
The support member serves as an intermediary structure between the fine-line coil and the external environment. It provides mechanical support and protection to the vulnerable thin coil traces, preventing them from deforming or shifting during the dicing process. This intermediary support structure enables the use of finer line widths without compromising manufacturing precision.
Data Source
AI summary
A thin film type inductor includes first, second and third exposed portions exposed to a first end surface of a body and fourth, fifth and sixth exposed portions exposed to a second end surface of the body opposing the first end surface of the body among external surfaces of the body. The first, second and third exposed portions are formed to be exposed symmetrically to the fourth, fifth and sixth exposed portions opposing the first, second and third exposed portions, respectively.