Wavy Cross-Section Inductor for Structural Stability
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Solution Overview
Problem
Existing power inductors face challenges in forming uniform coils with large aspect ratios due to limitations in manufacturing processes, leading to structural instability and reliability issues.
Innovation Solution
The inductor design includes a support member with a coil having a wavy cross-sectional shape and an encapsulant containing magnetic particles, with external electrodes connected to the coil, enhancing structural stability and reliability by increasing the contact area between the coil and the support member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a uniform coil with large aspect ratio is formed using conventional manufacturing processes, then the inductor size is reduced, but the manufacturing precision and structural stability deteriorate
Solution Approach 1:
The coil pattern cross section is designed with a wavy shape instead of a straight linear form. This curvature allows the coil to maintain structural stability while achieving a large aspect ratio, resolving the contradiction between size reduction and manufacturing precision by introducing a geometric form that naturally distributes stress and maintains uniformity.
Solution Approach 2:
The aspect ratio of the coil is increased by changing the geometric parameters of the coil pattern, specifically by creating a wavy cross-sectional shape. This parameter change allows the coil to fit within a smaller volume while maintaining manufacturing precision through the stabilizing effect of the wavy structure.
2Volume of moving object
If the coil aspect ratio is increased to reduce inductor size, then the inductor volume is reduced, but the structural stability and reliability worsen
Solution Approach 1:
The wavy cross-sectional shape of the coil pattern provides enhanced structural stability by distributing mechanical stress more evenly throughout the coil structure. This curvature prevents coil collapse and deformation that would otherwise occur with high aspect ratio straight coils, thereby maintaining reliability while reducing inductor volume.
Solution Approach 2:
The inductor uses a composite structure combining a support member, coil, and encapsulant with magnetic particles. This composite material approach enhances the overall structural stability of the high aspect ratio coil, preventing deformation and maintaining reliability while achieving compact volume.
3Ease of manufacture
If conventional coil structures are used, then the manufacturing process is simpler, but the contact area between coil and support member is insufficient leading to reliability issues
Solution Approach 1:
The wavy cross-sectional shape of the coil pattern naturally increases the contact area with the support member without adding complex manufacturing steps. The undulating surface creates more interface points for adhesion, improving reliability while maintaining ease of manufacture through a single patterning process.
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 allows for the stable formation of coils with high aspect ratios, improving direct current resistance and inductance characteristics while preventing coil collapse and deformation.
Implementation Method 1
an encapsulant encapsulating the support member and the coil
Implementation Method 2
at least some portion of a cross section of the coil pattern has a wavy shape
Data Source
AI summary
An inductor includes a body including a support member, a coil supported by the support member, and an encapsulant encapsulating the support member and the coil, the coil including a plurality of coil patterns continuously connected to each other and at least some portion of a cross section of the coil pattern having a wavy shape, and external electrodes disposed on an outer surface of the body and electrically connected to the coil.