Variable Thickness Lead Parts for Slim Inductor Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to manufacture slimmed electronic components, such as thin film inductors, while ensuring high performance and reliability, as existing methods face issues with breakage defects due to insufficient magnetic body regions around coil patterns, leading to vulnerability during processing.
Innovation Solution
The electronic component design includes a magnetic body with spiral coil patterns and lead parts of varying thicknesses, where thinner lead parts are formed closer to the outer region, and thicker regions are maintained for increased coupling force and reduced electric resistance, using a plating process to optimize the magnetic body's distribution and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inductor is slimmed down to meet device complexity and multifunctionalization requirements, then the component size is reduced, but the magnetic body region around coil patterns becomes insufficient leading to breakage defects
Solution Approach 1:
The lead parts are designed with variable thickness along their length, creating different local qualities: a first thickness in the initial portion for structural support and a second thickness in the second portion for stress reduction. This local differentiation allows the component to maintain reliability while achieving overall slimness.
Solution Approach 2:
The thickness parameter of the lead parts is changed along their length, transitioning from a first thickness to a second thickness. This parameter change enables the lead parts to provide both structural support and stress relief, resolving the contradiction between size reduction and breakage prevention.
2Strength
If the lead parts are made uniformly thick to ensure structural support, then breakage resistance is improved, but the component cannot achieve sufficient slimness
Solution Approach 1:
Different portions of the lead parts have different thicknesses to fulfill different functions: the initial portion has greater thickness for structural support and coupling force, while the second portion has reduced thickness to minimize volume and achieve slimness. This local quality differentiation resolves the contradiction between strength and size.
Solution Approach 2:
The lead parts are segmented into distinct thickness regions along their length, with a transition from first thickness to second thickness. This segmentation allows each portion to be optimized for its specific function, providing both structural support and size reduction.
3Volume of moving object
If the magnetic body region around coil patterns is reduced to achieve slimness, then component size is decreased, but manufacturing reliability deteriorates due to increased breakage defects
Solution Approach 1:
The lead parts exhibit local quality variation in thickness, with the initial portion having greater thickness to provide adequate magnetic body support region during manufacturing, while the second portion has reduced thickness to achieve overall slimness. This resolves the contradiction between manufacturing reliability and component size.
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 design enhances the reliability and performance of the electronic component by reducing stress on internal coil parts during processing, improving electrical characteristics and reducing defect rates, while maintaining the slimness of the component.
Implementation Method 1
The coil patterns may be formed by a plating process
Data Source
AI summary
An electronic component includes a magnetic body; and a coil pattern embedded in the magnetic body, the coil pattern including an internal coil part having a spiral shape and a lead part connected to an end of the internal coil part and exposed to an external surface of the magnetic body. The lead part includes at least two regions having different thicknesses, and the thickness of at least a portion of the lead part having a relatively thin thickness is thinner than a thickness of the internal coil part.