Coil Component Electrode Structure to Prevent Metal Filler Aggregation

The patent applies local quality by using two different types of metal fillers with distinct properties: spherical first fillers (e.g., copper particles of 3-10 μm) and flake-shaped second fillers (e.g., nickel particles of 1-5 μm). Each filler type contributes differently to the electrode structure, with spherical fillers providing conductivity and flake-shaped fillers forming a barrier against oxidation, creating localized functional zones within the electrode that collectively improve both conductivity and distribution uniformity.

The patent employs composite materials by combining multiple metal filler types (spherical copper particles and flake-shaped nickel particles) with a resin binder to create a conductive paste with optimized properties. This composite approach allows the electrode to simultaneously achieve high electrical conductivity from copper, oxidation resistance from nickel, and improved filler distribution, resolving the aggregation issue while maintaining conductivity.

The patent applies parameter changes by carefully controlling the particle size parameters of the metal fillers: spherical first fillers with diameter of 3-10 μm and flake-shaped second fillers with thickness of 1-5 μm. These specific size parameters prevent excessive aggregation during heat-curing while ensuring adequate metal content (60-90 vol%) for structural strength. The controlled particle size distribution maintains uniform filler arrangement and prevents weak spots in the electrode structure.

The composite structure of spherical and flake-shaped fillers creates a more robust electrode matrix. The spherical fillers provide structural support and conductivity pathways, while the flake-shaped fillers interlock to form a reinforcing network that prevents aggregation and enhances overall electrode strength. This composite filler system maintains structural integrity even after heat-curing.

The patent uses local quality by incorporating flake-shaped metal fillers (second fillers) that specifically address the resin portion problem. These flake-shaped particles distribute more uniformly throughout the resin matrix compared to spherical fillers alone, creating localized regions of improved homogeneity. The flake-shaped fillers act as spacers that prevent resin aggregation and maintain consistent material composition throughout the electrode, reducing environmental sensitivity.

The composite filler system creates a more homogeneous electrode structure by combining spherical and flake-shaped fillers with the resin binder. This multi-component composite prevents the formation of large resin portions that would create structural defects. The uniform distribution of diverse filler shapes and sizes throughout the electrode ensures consistent coefficients of linear expansion, preventing defect expansion during environmental changes such as thermal cycling.