Coil Component Intermetallic Compound Contact Resistance
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Solution Overview
Problem
Existing coil components have a reduced effective volume of magnetic material and increased contact resistance due to the configuration of external electrodes and lead-out patterns, which affects their performance in electronic devices.
Innovation Solution
A coil component design that embeds a support substrate within the body, featuring a coil portion with lead-out patterns exposed to the body's end surfaces and connection electrodes that penetrate the substrate, utilizing an intermetallic compound between the connection electrodes and lead-out patterns to reduce contact resistance and increase the effective volume of magnetic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external electrodes are formed on end surfaces of the body to connect to lead-out patterns, then electrical connection is achieved, but the length of the body is reduced and effective volume of magnetic material is reduced
Solution Approach 1:
The connection electrode is embedded within the lead-out pattern, with the connection electrode penetrating through the lead-out pattern to establish electrical connection. This nested configuration allows the connection structure to be integrated within the existing component volume rather than adding external protrusions, thereby maintaining the body length and preserving magnetic material volume while achieving reliable electrical connection.
2Reliability
If connection electrode directly contacts lead-out pattern, then electrical connection is established, but contact resistance is high
Solution Approach 1:
An intermetallic compound layer is introduced as an intermediary between the connection electrode and the lead-out pattern. This intermetallic compound serves as a mediator that facilitates better electrical contact and reduces contact resistance by creating a metallurgical bond between the two dissimilar metals, improving the quality of the electrical connection.
3Strength
If connection electrode includes base resin and metal particles, then flexibility and bonding are improved, but electrical conductivity may be reduced
Solution Approach 1:
The connection electrode structure is designed with local quality differentiation: the base resin and metal particles provide flexibility and bonding strength in the bulk material, while the conductive connection portion at the interface with the intermetallic compound ensures high electrical conductivity. This localized optimization allows different regions of the connection electrode to fulfill different functional requirements simultaneously.
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
The design enhances the effective volume of magnetic material and reduces contact resistance, thereby improving the performance and efficiency of the coil component in electronic devices.
Implementation Method 1
an intermetallic compound disposed between the connection electrode and the lead-out pattern
Data Source
AI summary
A coil component includes a body embedding a support substrate, an external electrode disposed on one surface of the body, and a coil portion disposed on the support substrate and including a lead-out pattern having one surface exposed to one end surface of the body abutting the one surface of the body. A connection electrode penetrates the lead-out pattern, extends to the external electrode, and has one surface exposed to the one end surface of the body. An intermetallic compound is disposed between the connection electrode and the lead-out pattern. The connection electrode includes a base resin, a plurality of metal particles disposed in the base resin, and a conductive connection portion surrounding the plurality of metal particles and in contact with the intermetallic compound.