Thin Inductor Support Wire Layout for Reduced Component Thickness
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Solution Overview
Problem
Existing inductor components require a thick insulating substrate for the rod body and protrusion, which increases the component thickness and complicates the optimization of electrical and mechanical functions.
Innovation Solution
The inductor component design includes an inductor wire with a pad connected to vertical and support wires, where the support wire extends parallel to the inductor wire and is exposed from the side surface, allowing for independent optimization of electrical and mechanical functions without the need for an insulating substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an insulating substrate is used to form the rod body and protrusion, then the mechanical support and positioning function is improved, but the thickness of the inductor component increases
Solution Approach 1:
The patent extracts the mechanical support function from the insulating substrate by introducing a separate support wire. The support wire is disposed on the pad on the opposite side of the wire main body and extends in parallel with the wire main body, providing the necessary mechanical support without requiring a thick insulating substrate. This separation of functions allows the insulating substrate to be thinner while maintaining adequate mechanical support.
Solution Approach 2:
The patent segments the functions previously performed by the insulating substrate into distinct components: the insulating substrate provides electrical insulation, while the support wire provides mechanical support. This segmentation allows each component to be optimized for its specific function, enabling reduction in overall thickness while maintaining both mechanical strength and electrical insulation.
2Length of stationary object
If the insulating substrate is removed and the inductor wire is used as substitute, then the thickness is reduced, but the mechanical function cannot be optimized independently from electrical function
Solution Approach 1:
The patent divides the electrical function (performed by the inductor wire) from the mechanical function (performed by the support wire). The support wire is specifically designed for mechanical support and positioning, while the inductor wire focuses on electrical function. This segmentation enables independent optimization of both electrical and mechanical properties without compromise.
Solution Approach 2:
The support wire serves multiple functions: it provides mechanical support, maintains positioning, and works in conjunction with the insulating substrate to ensure proper spacing. This multi-functionality allows the system to achieve adequate mechanical performance without requiring a thick insulating substrate, thereby reducing overall thickness while maintaining optimization capability.
3Device complexity
If the support wire is disposed on the pad with center axis on the same straight line as the wire main body, then the structure is simplified, but the mechanical support effectiveness is reduced
Solution Approach 1:
The patent introduces asymmetry in the positioning of the support wire by offsetting its center axis from the wire main body's center line. The support wire is disposed on the pad on the opposite side of the wire main body, creating an asymmetric configuration that enhances mechanical support effectiveness. This asymmetric positioning provides better leverage and support for preventing warpage while maintaining reasonable structural complexity.
Data Source
AI summary
A thin inductor component includes an element body having a principal surface and a side surface perpendicular to the principal surface. An inductor wire extends in parallel with the principal surface. From the inductor wire, a first vertical wire extends in a direction toward the principal surface, and a first support wire extends in parallel with the principal surface. The first vertical wire and the first support wire are connected to a first pad of the inductor wire. When a virtual tangent is drawn at a connection point of the inductor wire main body to the first pad with respect to the center axis of the wire main body when viewed from the thickness direction, the first support wire extends from the first pad in parallel with the virtual tangent and the center axis of the first support wire and the virtual tangent are located on different straight lines.