Coil Component Electrode Interface for Edge Insulation Coverage
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Solution Overview
Problem
The existing manufacturing process for coil components faces challenges in collectively forming an insulating layer on the surface of the body, particularly on edges, and achieving a strong adhesive force between the body and external electrodes, due to limitations in printing insulating layers on multiple surfaces and edges.
Innovation Solution
A coil component design that includes a sacrificial layer disposed on the surface where external electrodes are formed, allowing for the collective formation of an insulating layer on the body surface, with a recess on the edges to improve contact area and adhesive force by varying the surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an insulating layer is printed on multiple surfaces (upper, side, lower) of the body individually, then the insulating layer can be formed on each surface, but it is difficult to collectively form the insulating layer on the entire surface including edges
Solution Approach 1:
A sacrificial layer is disposed on the body surface in advance, specifically on regions where external electrodes will be formed. This preliminary action enables subsequent collective formation of the insulating layer over the entire surface including edges, while the sacrificial layer protects specific areas from insulation. The sacrificial layer is later removed to expose the underlying structure where electrodes should contact the body.
Solution Approach 2:
The sacrificial layer acts as an intermediary element between the body and the insulating layer formation process. It temporarily occupies the space where external electrodes need to contact the body, allowing the insulating layer to be collectively formed on all other surfaces and edges without compromising electrode contact areas. This intermediary approach resolves the conflict between collective insulation and edge coverage.
2Ease of manufacture
If a sacrificial layer is disposed on the body surface to enable collective insulating layer formation, then the insulating layer can be formed on the entire surface, but adhesive force between the body and external electrode may be reduced
Solution Approach 1:
The sacrificial layer is selectively removed (taken out) from specific regions of the body surface where external electrodes need to make contact. This extraction process occurs after the insulating layer has been collectively formed on the entire surface. By removing the sacrificial layer only in electrode contact regions, the patent maintains collective insulation coverage while restoring direct body-electrode contact and adhesive force in the necessary areas.
Solution Approach 2:
The sacrificial layer is disposed preliminarily to enable collective insulating layer formation, then subsequently removed to restore adhesive properties. This two-stage preliminary action (first adding, then removing) allows the process to achieve collective insulation while ultimately providing strong adhesive force between the body and external electrodes where needed.
3Manufacturing precision
If the insulating layer is formed by individual printing processes on each surface, then each surface can be insulated, but the insulating layer cannot be formed on edge portions of the body
Solution Approach 1:
The sacrificial layer is disposed in advance on the body surface before the insulating layer formation process. This preliminary disposition enables a single collective printing or coating operation to cover the entire surface including edges, as the sacrificial layer defines the pattern areas where insulation should not occur. This approach dramatically increases total surface area coverage compared to individual surface printing.
Solution Approach 2:
The patent transitions from a multi-dimensional approach (individual printing on upper, side, and lower surfaces separately) to a single-plane approach (collective formation on the entire surface at once). By disposing the sacrificial layer on the body surface and then collectively forming the insulating layer, the process achieves edge coverage that was previously impossible with individual surface printing methods.
Data Source
AI summary
A coil component includes a support substrate, a coil portion disposed on at least one surface of the support substrate, a body including the support substrate and the coil portion disposed therein, an external electrode disposed on a surface of the body and connected to the coil portion, and an insulating layer disposed in a region of the surface of the body other than a region in which the external electrode is disposed, wherein an average roughness (Ra) of the surface of the body in contact with the external electrode is different from an average roughness (Ra) of the surface of the body in contact with the insulating layer.