Patent Publication Number: US-2005140486-A1

Title: Multi-layer chip inductive element

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates generally to electronic components, and more particularly to a multi-layer chip inductive element.  
      2. Description of the Related Art  
      A conventional chip bead element is a structurally miniature inductive admixture of conductor patterns and powder of ferrite oxide that are stacked upon one another.  
      However, the aforementioned conventional chip bead element is defective and needs to be improved. It is well known in the prior art that higher inductance needs more inductive coils. When the coils that have to be made by through-hole process are densely increased inside the chip bead element, the production of the chip bead element becomes slower and more difficult to further incur more defective fraction. If the chip bead element is arranged upright, the height will be increased to incur difficulty for the production while the coils are increased.  
     SUMMARY OF THE INVENTION  
      The primary objective of the present invention is to provide a multi-layer chip inductive element that inductive coils are formed in sectors so as not to lengthen or heighten the whole structure of the element while the inductive coils are increased.  
      The secondary objective of the present invention is to provide a multi-layer chip inductive element that facilitates the production to enhance the yield.  
      The foregoing objectives of the present invention are attained by the multi-layer chip inductive element that includes at least two inductors connected with each other and mounted in an insulating ceramic material. Each of the inductors has a longitudinal axle parallel to the other and includes a plurality of conductor patterns and ceramic layers stacked upon one another in sectors, wherein inductive coils of each two adjacent inductors of the inductors are wound conversely to form sectors thereof. Accordingly, the coils can be increased without lengthening and heightening the element to further facilitate the production and enhance the yield. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective view of a preferred embodiment of the present invention;  
       FIG. 2  is a schematic view of the preferred embodiment of the present invention, illustrating a manufacturing step;  
       FIG. 3  illustrates the manufacturing step implemented after the step illustrated in  FIG. 2 ;  
       FIG. 4  illustrates the manufacturing step implemented after the step illustrated in  FIG. 3 ;  
       FIG. 5  illustrates the manufacturing step implemented after the step illustrated in  FIG. 4 ;  
       FIG. 6  illustrates the manufacturing step implemented after the step illustrated in  FIG. 5 ;  
       FIG. 7  illustrates the manufacturing step implemented after the step illustrated in  FIG. 6 ;  
       FIG. 8  illustrates the manufacturing step implemented after the step illustrated in  FIG. 7 ;  
       FIG. 9  is another perspective view of the preferred embodiment of the present invention having three inductors; and  
       FIG. 10  is another perspective view of the preferred embodiment of the present invention having four inductors. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to  FIG. 1 , a multi-layer chip inductive element  10  includes at least two inductors  11  which are embodied as two adjacent inductors  11 .  
      The two inductors  11  are connected with each other and are mounted in an insulating ceramic material  13 . Each of the two inductors  11  has a longitudinal axle parallel to the other and has a plurality of inductor patterns and ceramic layers stacked upon one another in sectors. Inductive coils of the two inductors are conversely coiled to be formed in sectors. When the inductor patterns are stacked upon one another, the inductor patterns are partially contacted one another.  
       FIGS. 1-8  illustrate manufacturing process of the present invention steps by steps. As shown in  FIGS. 2 , when the present invention is manufactured, two first conductor patterns A 1  and B 1  are disposed on an insulating ceramic material  13 . Because the inductive coils of the two conductors  11  are conversely coiled, the two first conductor patterns A 1  and B 1  are different in shape. As shown in  FIG. 3 , a ceramic layer C 1  is disposed on the two first conductor patterns A 1  and B 1  and parts of the two first conductor patterns A 1  and B 1  are exposed outside. As shown in  FIG. 4 , two second conductor patterns A 2  and B 2  are stacked upon the ceramic layer C 1  and respectively contact the two first conductor patterns A 1  and B 1 . As shown in  FIG. 5 , another ceramic layer C 2  is disposed on the two second conductor patterns A 2  and B 2  and parts of the two second conductor patterns A 2  and B 2  are exposed outside. As shown in FIG.  6 , two third conductor patterns A 3  and B 3  are stacked upon the ceramic layer C 2  and respectively contact the two second conductor patterns A 2  and B 2 . As shown in  FIG. 7 , one another ceramic layer C 3  is disposed on the two third conductor patterns A 3  and B 3  and parts of the two third conductor patterns A 3  and B 3  are exposed outside. As shown in  FIG. 8 , a linking conductor pattern D 4  is disposed on the ceramic layer C 3  and interconnects the two third conductor patterns A 3  and B 3 . Thus, the multi-layer chip inductive element  10 , as shown in  FIG. 1 , is formed by that the two inductors  11  are interconnected and conversely coiled. In addition, repeat the steps illustrated in  FIGS. 4-7  to increase the number of the coils of the inductors  11 .  
      Referring to  FIG. 1 , the two inductors  11  are connected with each other and are conversely coiled. Although the two inductors  11  are structurally axially parallel to each other, the two inductors  11  are connected with each other to be tandem connected, such that the inductance of the multi-layer chip inductive element  10  is the total amount of the inductance of the two inductors  11 . Accordingly, the inductance of the present invention can be increased by the two parallel arranged and tandem connected inductors within a predetermined height, and the inductors  11  are formed in sectors inside the insulating ceramic material  13 , such that increasing coils of the inductors  11  will not heighten the element  10 .  
      Please note that the aforementioned  FIGS. 2-8  merely illustrate the manufacturing process of the inductors to be the insignificant technical feature of the present invention. The present invention focuses on the significant technical feature that the inductors are formed in sectors and axially parallel to each other without heightening the element.  
      Referring to  FIGS. 9-10 , the present invention can alternatively include three inductors  11 ′ or four inductors  11 ″ to attain the primary and secondary objectives and to further generate higher inductance.  
      In conclusion, the present invention includes the following advantages.  
      1. The inductive coils of the present invention can be formed in sectors and can be increased in number without heightening the element to further improve the defective of the prior art.  
      2. The height and the length of each inductor of the present invention can be kept regular to avoid irregular height or length that makes it difficult for the production, such that the production yield of the present invention can be kept invariable to enable the production in advantageous condition.