Vertical Inductor Wire Design for Low DC Resistance
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Solution Overview
Problem
Inductor components face limitations in increasing wiring length while maintaining low DC electric resistance, particularly in power inductors where a balance between current and inductance is crucial.
Innovation Solution
The design incorporates a rectangular parallelepiped element body with inductor wires extending parallel to its main face, featuring a unique configuration of vertical wires and pads, allowing for a longer wiring length without excessive DC electric resistance by optimizing the dimensions and arrangement of the inductor wires and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inductor wire is configured in a linear or meander shape to increase wiring length, then the inductance value increases, but the DC electric resistance increases
Solution Approach 1:
The patent transitions from planar spiral winding to three-dimensional vertical wire extension. The inductor wire extends vertically from the substrate surface along the thickness direction, utilizing the Z-dimension to achieve long wiring length without increasing in-plane area. This dimensional transition allows sufficient wiring length for high inductance while maintaining low DC resistance by avoiding excessive planar expansion.
Solution Approach 2:
The patent employs asymmetric element body dimensions where the length in the first direction is 2.5 times or more the width in the second direction. This asymmetric configuration optimizes the wiring path arrangement, allowing the inductor wire to achieve sufficient length in the extended first direction while controlling resistance through the optimized geometric ratio.
2Volume of stationary object
If the element body is made compact to reduce size, then the component becomes smaller, but the wiring length is insufficient
Solution Approach 1:
The patent resolves the size-length contradiction by extending the wire in the thickness direction (vertical dimension) rather than expanding the element body footprint. The inductor wire protrudes vertically from the substrate, enabling sufficient wiring length within a compact planar footprint, thus achieving both small component size and adequate wiring length.
Solution Approach 2:
The inductor wire is configured to extend vertically from the substrate surface in advance, with the wiring body formed within the element body and the wire end exposed on the surface. This preliminary vertical extension ensures sufficient wiring length is achieved before final component assembly, allowing compact packaging while maintaining required wire length for inductance.
3Volume of moving object
If the inductor wire is arranged in multiple rows to increase wiring length, then the inductance value increases, but the device complexity increases
Solution Approach 1:
The patent divides the inductor wire into multiple segments arranged in parallel rows within the element body. Each segment extends vertically and connects to corresponding pads on the substrate. This segmentation allows the total inductance to be the sum of individual segment inductances, achieving high inductance value while maintaining manageable structural complexity through modular parallel arrangement.
Data Source
AI summary
An inductor component includes a rectangular parallelepiped element body inside which a inductor wire extends in the first layer. The inductor wire includes a wiring body extending linearly, and first and second pads at first and second ends, respectively, of the wiring body. Of the surface of the element body, the dimension of the upper main face in the thickness direction in the longitudinal direction is 2.5 times or more the dimension of the main face in the short direction. When viewed from the thickness direction, the smallest rectangular region that is divided by a long side extending in the longitudinal direction and a short side extending in the short direction and that surrounds the whole wiring body is defined as an inductor region. The dimension of the first side of the inductor region is three times or more the dimension of the second side of the inductor region.