Coil Component Corner Lead Placement for Square Body
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Solution Overview
Problem
The challenge in manufacturing coil components with a square-shaped lower surface, where the length and width are equal, is that it is difficult to specify the side surface for forming lead portions and external electrodes, leading to increased manufacturing complexity and cost.
Innovation Solution
Forming lead portions of the coil conductor in the corner regions of the body, allowing for external electrodes to be connected without specifying the surface, which reduces manufacturing complexity and cost, and improves yield by reducing warpage through line-symmetrical coil conductor formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component has a square-shaped lower surface with equal length and width, then the component achieves compactness and multi-functionalization, but it becomes impossible to specify the side surface for lead portions and external electrodes, increasing manufacturing complexity
Solution Approach 1:
The patent applies asymmetry by positioning the lead portions at corner regions rather than central portions of side surfaces. This asymmetric placement breaks the rotational symmetry of the square component, creating unique identification features that enable manufacturers to correctly orient and assemble the component without complex marking systems, thereby reducing manufacturing complexity while maintaining the compact square form factor
2Device complexity
If the lead portions are formed at central portions of side surfaces, then the component structure is simple, but it becomes difficult to specify the side surface for external electrode formation, leading to increased manufacturing time and cost
Solution Approach 1:
The patent implements preliminary action by pre-positioning the lead portions at the corner regions during the component fabrication process. This preliminary placement of asymmetric features serves as built-in orientation markers that guide subsequent manufacturing steps, including external electrode formation and assembly operations, thereby reducing manufacturing time without significantly increasing component structural complexity
Data Source
AI summary
A coil component includes: a body in which a support member is disposed; and first and second coil conductors formed on first and second surfaces of the support member, respectively, the second surface of the support member opposing the first surface thereof, and including first and second lead portions extended to be exposed to the outside of the body, respectively. The first and second lead portions are formed in corner regions of the body.