Coil Component Outer Electrode Adhesion via Insulating Layer Width
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Solution Overview
Problem
The adhesion force between the outer electrode and the multilayer body in coil components tends to weaken with size reduction, leading to a risk of peeling off under mechanical stress, compromising the reliability of the components.
Innovation Solution
A coil component design featuring a multilayer body with a first magnetic layer, an insulating layer, and a second magnetic layer, where the outer electrodes have wider portions contacting the insulating layer than the magnetic layers, enhancing adhesion through material interactions, such as glass and ferrite components, and optimizing electrode placement to reduce short circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the outer electrode is reduced to achieve component miniaturization, then the component size is reduced, but the adhesion force between the outer electrode and the multilayer body weakens
Solution Approach 1:
The outer electrode is designed with different widths at different locations: a first width when contacting the magnetic layer and a second width when contacting the insulating layer, where the second width is greater than the first width. This local variation in geometry concentrates the adhesion function at the insulating layer interface, compensating for the overall size reduction of the electrode.
Solution Approach 2:
The multilayer body comprises alternating magnetic layers and insulating layers with different material properties. The insulating layer provides both electrical insulation and enhanced adhesion to the outer electrode, creating a composite structure that simultaneously achieves miniaturization and maintains strong electrode attachment.
2Volume of moving object
If the outer electrode size is reduced, then the component size is reduced, but the reliability of the coil component decreases due to peeling risk
Solution Approach 1:
The outer electrode features a localized width increase at the insulating layer contact portion, creating a specific adhesion enhancement zone. This local geometric modification ensures reliable attachment and prevents peeling under mechanical stress, maintaining component reliability despite overall size reduction.
Solution Approach 2:
The insulating layer acts as an intermediary between the outer electrode and the magnetic layer, providing a contact interface with superior adhesion properties. This intermediate layer prevents direct contact between the electrode and magnetic material while ensuring mechanical stability and electrical insulation.
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 significantly increases the adhesion force between the outer electrode and the multilayer body, preventing peeling and enhancing the electrical reliability of the coil component, even at smaller sizes.
Implementation Method 1
when the outer electrode contains glass, the adhesion force between the outer electrode and the multilayer body can be further increased due to interaction between a glass component contained in the outer electrode and a glass component contained in the insulating layer
Data Source
AI summary
A coil component including a multilayer body, at least one coil provided inside the multilayer body, and outer electrodes disposed on at least one surface of the multilayer body. The multilayer body includes a first magnetic layer, an insulating layer laminated on the first magnetic layer, and a second magnetic layer laminated on the insulating layer. The coil has, at both ends thereof, lead-out portions, each of which extends up to the surface of the multilayer body and is connected to a respective one of the outer electrodes. The outer electrodes are each present over surfaces of the first magnetic layer, the insulating layer, and the second magnetic layer, and a width of a portion of at least one of the outer electrodes contacting the insulating layer is larger than widths of each of portions of that outer electrode contacting the first and second magnetic layers.