Thin-Film Coil Electrode Structure for Vibration-Resistant Coupling
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Solution Overview
Problem
Existing thin-film coil components face challenges in maintaining connection reliability between the coil and external electrodes due to reduced coupling force, especially under vibrations or external impacts.
Innovation Solution
The coil component design includes a body with a recessed area, where one region of the external electrode's end is bent toward the recess, enhancing the physical coupling force between the body and the external electrode. Additionally, a conductive resin layer and adhesive layers are used to strengthen the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a thin-film coil component is used to achieve miniaturization, then the size is reduced, but the coupling force between the external electrode and the coil is reduced
Solution Approach 1:
The external electrode is extended to wrap around and contact the side surface of the coil, transitioning from a single-plane connection to a three-dimensional multi-surface connection. This dimensional extension increases the contact area and coupling force without increasing the overall component size
Solution Approach 2:
The external electrode is formed with a bent or curved shape that conforms to the cylindrical side surface of the coil, allowing optimal contact along the curved geometry. This curvature-based design maximizes the contact area between the electrode and coil surface
2Volume of moving object
If the coupling force is reduced in miniaturized components, then the size is smaller, but the connection reliability under vibrations or shocks is reduced
Solution Approach 1:
The external electrode contacts the coil at multiple locations including the top surface and side surface, creating a multi-point connection that distributes mechanical stress and maintains electrical connection reliability under vibration and shock conditions
Solution Approach 2:
The bent shape of the external electrode allows it to conform to the coil's cylindrical geometry, providing continuous contact along the curved surface that maintains connection stability under mechanical stress
Data Source
AI summary
According to an aspect of the present disclosure, a coil component includes a body including a first surface and a second surface opposing each other in a first direction, and a third surface connecting the first surface to the second surface; a coil disposed in the body and including a lead-out portion led out to the first surface or the second surface; and an external electrode disposed on the body and connected to the lead-out portion and including a first metal layer and a second metal layer. The first metal layer includes a first side surface facing the body and a second side surface opposing the first side surface, and the second metal layer is disposed on each of the first side surface and the second side surface of the first metal layer.