Embedded Coil Terminal Electrode Layout for Mounting Alignment

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Solution Overview

Problem

The existing coil components with alternately stacked conductor and interlayer insulating layers face challenges in forming terminal electrodes into desired shapes, as they are typically formed by electrolyte plating, limiting flexibility in design and increasing the likelihood of misalignment during mounting.

Innovation Solution

The use of conductive paste for terminal electrodes, which allows for the formation of desired planar shapes, including protruding parts and recesses, to cover and expose electrode patterns effectively, reducing misalignment and solder spread during mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If electrolyte plating is used to form terminal electrode, then manufacturing process is conventional and reliable, but terminal electrode cannot be formed into desired planar shape

Engineering Contradiction:

Improveplanar shape of terminal electrodeVSAvoidmanufacturing process flexibility

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent changes the material state and formation method of the terminal electrode from electrolyte plating (deposited layer) to conductive paste (applied material). This parameter change enables the terminal electrode to be formed into desired planar shapes including protruding parts that extend beyond the electrode patterns, providing design flexibility while maintaining manufacturing simplicity through screen printing or similar paste application methods.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If terminal electrode is formed to cover electrode patterns completely, then electrical connection is ensured, but misalignment during mounting increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmounting position alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent segments the terminal electrode into functionally distinct regions: a first area that covers the electrode patterns for electrical connection, and second/third areas that extend beyond the patterns to serve as positioning features. This segmentation allows the electrode to simultaneously ensure reliable electrical connection through the covered region while providing mounting alignment guidance through the protruding portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal electrode employs asymmetric geometry with protruding parts (first, second, and third areas) that extend beyond the underlying electrode patterns. This asymmetric design creates distinctive positioning features that guide correct placement during mounting, reducing misalignment while the covered first area maintains electrical connection reliability.

Inventive Principle:

Principle #4Asymmetry

3Reliability

If solder fillet spreads on side surface of magnetic member, then electrical connection may be compromised, but preventing spread limits design flexibility

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidterminal electrode shape freedom

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies preliminary anti-action by designing the terminal electrode with protruding parts that extend beyond the electrode patterns and positioned to prevent solder fillet from spreading onto the side surface of the magnetic member. This proactive geometric design stops the harmful solder spread before it can occur, while the conductive paste material maintains design flexibility for various electrode configurations.

Inventive Principle:

Principle #9Preliminary anti-action

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

This approach enables the formation of terminal electrodes with specific shapes that minimize misalignment and solder spread, facilitating high-density mounting and precise positioning of coil components.

Implementation Method 1

a terminal electrode made of a conductive paste

Methodology Applied

Scientific EffectConductive paste deposition: Deposition (physical)

Data Source

PatentUS20240170202A1Coil component

Publication Date: 2024.05.23 TDK CORP

AI summary

To improve a coil component having a structure in which a coil part is embedded in a magnetic member. A coil component includes a coil part embedded in the magnetic members and terminal electrodes each made of a conductive paste. Conductor layers constituting the coil part respectively have coil conductor patterns and electrode patterns exposed from a mounting surface. The terminal electrode has an area provided at a position covering the electrode patterns on the mounting surface and areas provided at positions not covering the electrode patterns on the mounting surface. A part of the area constitutes a protruding part protruding in the x-direction. The terminal electrode thus has the protruding part, thereby making misalignment of mounting position in the z-direction less likely to occur at the time of mounting.