Coil Component Electrode Layout to Prevent Plating Bleeding
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Solution Overview
Problem
Plating bleeding occurs during the formation of small-sized coil components, leading to external electrodes extending beyond the target position, and the need for an additional process to remove dicing burrs.
Innovation Solution
A coil component design with a support substrate, insulating layers, and external electrodes that prevent plating bleeding by spacing connection portions away from the component edges and omitting the grinding process for burr removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component is formed using a plating process to decrease in size, then the component size is reduced, but plating bleeding causes external electrodes to extend beyond the target formation position
Solution Approach 1:
An insulating layer is introduced as an intermediary between the plating process and the external electrode formation. This insulating layer prevents plating bleeding from causing electrode material to extend beyond the target position, while still allowing the electrode to make electrical contact through openings in the insulating layer.
Solution Approach 2:
The insulating layer is formed on the electrode surface before the plating process occurs. This preliminary action creates a barrier that controls where plating material can deposit, preventing bleeding while maintaining the desired electrode geometry and position.
2Productivity
If a dicing process is used to cut the coil component, then the component can be separated into individual units, but burring is generated that requires an additional removal process
Solution Approach 1:
The insulating layer formation process is merged with the dicing process timing. The insulating layer is formed to extend to the edges of the electrode, and when dicing occurs, this insulating layer prevents burr generation at the cut surfaces, eliminating the need for a separate burr removal process.
Solution Approach 2:
The insulating layer that extends to the electrode edges, which might seem like excess material, actually serves a beneficial function during dicing by preventing burr formation. The harmful effect of potential burrs is converted into a benefit where the insulating layer protects against burr generation in the first place.
3Volume of moving object
If the connection portion is positioned close to the edge for compact design, then space is saved, but plating bleeding occurs and connectivity reliability decreases
Solution Approach 1:
The insulating layer serves as a mediator that allows the connection portion to be positioned close to the edge for compact design while preventing plating bleeding from compromising connectivity reliability. The insulating layer blocks unwanted plating material while maintaining electrical connectivity through controlled openings.
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
Prevents plating bleeding and reduces process lead time by integrating insulating layers to control electrode extension and eliminates the need for post-dicing burr removal, enhancing connectivity and reliability.
Implementation Method 1
a first insulating layer disposed on the one end surface of the body, and having an opening disposed on a surface of the first lead-out pattern extending from the one end surface of the body and on at least a portion of the one end surface of the body
Implementation Method 2
a cover insulating layer disposed on the one end surface of the body to cover the first connection portion
Data Source
AI summary
A coil component includes: a body; a coil portion disposed in the body and including a lead-out pattern exposed on one end surface of the body; an insulating layer disposed on the one end surface of the body and having an opening disposed on the lead-out pattern; an external electrode including a connection portion, disposed to be in contact with the lead-out pattern, and a pad portion extending from the connection portion to one surface of the body; and a cover insulating layer disposed on the one end surface of the body to cover the connection portion. The connection portion is spaced apart from all corner portions of the one end surface of the body, except for a corner portion between the one end surface of the body and one surface of the body, on the one end surface of the body.