Coil Component External Electrodes Low Resistance Oxidation
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Solution Overview
Problem
Existing coil electronic components, such as inductors, face challenges in maintaining low electrical resistance and preventing metal oxidation, which degrades their electrical characteristics due to the use of resin electrodes for forming external electrodes.
Innovation Solution
A coil electronic component design featuring multiple layers with exposed connection patterns, conductive vias, and multilayer external electrodes, including flexible electrodes with insulating resin and conductive particles, which improves electrical connectivity and resistance characteristics without the need for high-temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin electrodes are used to form external electrodes at low temperature, then metal oxidation is prevented, but electrical resistance increases and electrical characteristics deteriorate
Solution Approach 1:
The external electrode is segmented into multiple functional layers: a flexible electrode layer (with low electrical resistance) and a resin electrode layer (for oxidation prevention and bonding). This segmentation allows each layer to perform its specialized function, resolving the contradiction between low resistance and oxidation prevention.
Solution Approach 2:
The external electrode uses a composite structure combining flexible electrode material (providing low electrical resistance) and resin electrode material (providing oxidation protection and mechanical bonding). This composite approach enables simultaneous achievement of low resistance and oxidation prevention.
2Temperature
If external electrodes are formed at low temperature, then metal oxidation is prevented, but electrical characteristics are deteriorated
Solution Approach 1:
The electrode formation process is segmented into two stages: first forming the flexible electrode at low temperature (preventing oxidation), then forming the resin electrode at low temperature (maintaining oxidation prevention). The flexible electrode material compensates for the low-temperature formation limitation by providing inherently low resistance.
Solution Approach 2:
The invention changes the material parameter of the external electrode by introducing flexible electrode material with inherently low electrical resistance, allowing low-temperature formation while maintaining good electrical characteristics. This parameter change resolves the contradiction between temperature and electrical characteristics.
3Manufacturing precision
If connection patterns are exposed from the coil electronic component, then electrical connectivity between layers is improved, but manufacturing complexity increases
Solution Approach 1:
The connection pattern and external electrode are merged into an integrated structure where the flexible electrode directly contacts the exposed connection pattern, and the resin electrode provides both protection and bonding function. This merging simplifies the overall structure while maintaining good electrical connectivity.
Solution Approach 2:
The flexible electrode acts as an intermediary between the exposed connection pattern and the resin electrode, providing direct electrical contact while the resin electrode provides mechanical support and protection. This intermediary structure achieves good connectivity without excessive complexity.
Data Source
AI summary
A coil electronic component includes a plurality of coil layers including coil patterns and connection patterns. The coil patterns are disposed between the connection patterns. The connection patterns are at least partially exposed from the coil electronic component. The coil electronic component further includes connection electrodes connecting the connection patterns formed in different coil layers of the plurality of coil layers with each other, and external electrodes connected to the connection electrodes and at least partially enclosing the connection electrodes.