Small Power Inductor of 4 mm by 4 mm Square for Automotive Use

As the computerization of cars advances, ECUs are now incorporated in several cars. ADAS and autonomous driving require a number of ECUs capable of highly efficient control over cars, with such ECUs requiring small and high-performance power inductor free from connection failures.
The company has commercialized a small power inductor of 4 mm by 4 mm square for automotive use. It is manufactured with a molding technology where the coil is completely filled with a melted metal composite material, and is highly resistant to vibrations, thereby preventing crack formation. Further, its leads have a redundant design that improves the connection reliability of the coil.

Small Power inductor of 4 mm by 4 mm Square for Automotive Use

What is small power inductor of 4 mm by 4 mm square for automotive use?

*1: Cleanliness is measured in accordance with VDA19.1: technical cleanliness inspection and ISO16232: cleanliness measurement standards, etc.

1. Suppress the bias of magnetic material density to prevent the formation of cracks inside the product.

By utilizing its unique metal magnetic material, the company has newly developed a metal composite material for insulating magnetic powder and sealing the metal magnetic material. This enabls uniform density of the metal magnetic material which is required for compact-sizing, and brought power inductor that suppresses crack formation in the product.

[Challenge to compact-sizing]

(Structure image)

構造イメージ

[Problem solution]

(Metal composite material image)

Metal composite material image

2. A joint with a redundant design between a built-in coil and a terminal improves the connection reliability.

・Structure for suppressing connection defects by applying redundant design that has multiple connections to the lead.
・Improved connection reliability of the lead by applying "caulking" structure to the lead terminal.

Redundant design of a connection

(Each lead has its two parts connected.)

Suppressing connection defect generation by applying redundant design that has multiple connection points

Process of caulking and welding at the connection

*Each lead has two caulked and welded parts.

Welding quality improvement
by applying "caulking" at the terminal

3. CO2 emissions during the manufacturing process are 50% less than in conventional cases (CO2 emissions/piece)

Due to its smaller size than conventional ones, the product requires finer processing and assembly, resulting in a problem whereby the conventional manufacturing process needs a greater amount of power to manufacture the product. To deal with this problem, Panasonic has changed the processing method by reducing heat treatments, thereby allowing simultaneous microfabrication and high-speed processing. This has led to a significant improvement in the productivity of the production process. As a result, CO2 emissions during the manufacturing process are now 50% less than in conventional cases (CO2 emissions/unit).

Metal composite material
for a 4 mm by 4 mm square coil (image)

Metal composite material for a 4 mm by 4 mm square coil (image)

Use example

[Sensor system application for supporting ADAS/AD]

Sensor system application for supporting ADAS/AD

Circuit example Above application Voltage-down DC-DC converter

Circuit example   Above application   Voltage-down DC-DC converter

Lineup

Product number Shape
W×D×H (mm)
Inductance(*1)
(µH)
DC resistance
20℃ (mΩ)
Rated current (*2)
(A)
ETQP2MR22PGR 4.45 x 4.06 x 2.0 0.22 7.7 8.3
ETQP2M2R2PGR 2.2 54 3.2

(*1): Measured at 100 kHz. (*2): Current value that causes a temperature rise of 40°C

The company is planning to expand the inductance range of the coil
to meet market needs.