Recessed External Electrode Structure for Stable PCB-Mounted Coil Components
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Solution Overview
Problem
Existing coil components face challenges in being smaller and low-profile while maintaining reliability when mounted on a printed circuit board, leading to unintentional rotation and reduced bonding strength due to insufficient mounting area.
Innovation Solution
A coil component design featuring a body with a molded portion and cover portion, a wound coil, external electrodes with grooves, and recess portions to enhance stability and bonding, utilizing magnetic materials and insulating resins for structural support and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component is made smaller and low-profile, then the component size is reduced, but the mounting area on the external electrode becomes insufficient
Solution Approach 1:
The patent introduces recess portions that extend downward from the surface of the external electrode, utilizing the vertical dimension (thickness direction) to increase the effective mounting area. This allows the component to maintain a small footprint on the board surface while providing sufficient bonding area through the recessed regions, effectively resolving the contradiction between small component size and adequate mounting area.
2Stability of the object's composition
If the mounting area is increased to prevent rotation, then the component stability is improved, but the component height increases
Solution Approach 1:
Instead of increasing the horizontal footprint to improve stability, the patent uses recess portions that extend vertically downward from the external electrode surface. This vertical expansion provides increased bonding area and rotational prevention without increasing the component's overall height, as the recess portions are formed within the existing electrode structure rather than adding external height.
Solution Approach 2:
The recess portions are nested within the external electrode structure, creating a multi-level mounting surface. The groove is formed within the recess portion, creating a nested configuration that maximizes the use of available space within the electrode thickness, providing enhanced stability without external height increase.
3Strength
If the groove is formed in the external electrode, then the bonding strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines the formation of the recess portion and the groove into a single integrated structure on the external electrode. The groove is formed within the recess portion, and both features are created during the same electrode formation process, merging multiple potential manufacturing steps into one operation. This reduces manufacturing complexity while still providing the enhanced bonding strength from the recessed groove structure.
Data Source
AI summary
A coil component includes: a body including a molded portion having one surface and the other surface opposing each other, and a cover portion disposed on the one surface of the molded portion; a wound coil disposed between the molded portion and the cover portion in the body, and having first and second lead-out portions extending to one surface of the body; a first recess portion disposed in the one surface of the body; a first external electrode disposed on the one surface of the body to be connected to the first lead-out portion, and disposed along a surface of the first recess portion to have a first groove disposed therein; and a second external electrode disposed on the one surface of the body and connected to the second lead-out portion.