Coil Component Electrode Protrusion for Peeling Resistance
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Solution Overview
Problem
The existing laminated inductor designs are prone to terminal electrode peeling due to bending stress applied to the mounting substrate, which can lead to cracks in the element body.
Innovation Solution
A coil component design featuring first and second electrode parts with protrusions embedded in the element body, where the electrode parts have a low glass content and increased surface roughness, and are strategically positioned to disperse shear stress, thereby preventing peeling and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal electrode is directly mounted on the mounting substrate, then the electrode can be easily connected to the substrate, but the electrode peels off due to bending stress
Solution Approach 1:
The electrode part is extended in the thickness direction of the element body by forming a protrusion that penetrates through the element body. This dimensional extension allows the electrode to span across the interface between the mounting substrate and the element body, providing mechanical anchoring that prevents peeling while maintaining electrical connection.
Solution Approach 2:
The protrusion of the electrode part is formed in advance during the manufacturing process to penetrate the element body before mounting. This preliminary structural preparation ensures that when bending stress occurs during operation, the electrode is already anchored and can resist the peeling force effectively.
2Stability of the object's composition
If the electrode part is made with high glass content to match the element body, then the material composition is uniform, but the electrode is more likely to break under bending stress
Solution Approach 1:
The electrode part is designed with locally different material properties from the element body. Specifically, the glass content in the electrode part is controlled to be lower than in the element body, making the electrode more ductile and flexible. This local quality difference allows the electrode to withstand bending stress without breaking while the element body maintains its structural integrity.
Solution Approach 2:
The glass content parameter of the electrode part is specifically adjusted to be lower than that of the element body. This parameter change modifies the mechanical properties of the electrode, making it more stretchable and less prone to brittle failure under bending stress, while maintaining electrical conductivity and compositional stability.
3Device complexity
If the electrode part is made smooth to reduce manufacturing complexity, then the manufacturing process is simpler, but the electrode peels off more easily
Solution Approach 1:
Instead of increasing surface roughness in the planar direction, the solution extends the electrode in the thickness direction by forming a protrusion. This dimensional change provides mechanical interlocking with the element body, achieving strong bonding without requiring complex surface treatment processes, thus maintaining manufacturing simplicity while improving peeling resistance.
Data Source
AI summary
The coil component includes an element body, a coil, a first electrode part and a second electrode part. The element body includes a main surface to be used as a mounting surface. The coil is disposed in the element body. The first electrode part and the second electrode part are spaced apart from each other in a first direction, embedded in the element body in such a way as to be exposed from the main surface, and electrically connected to the coil. The first electrode part includes a first surface exposed from the main surface and a protrusion disposed in the element body in such a way as to be spaced apart from the main surface. The protrusion protrudes more toward the second electrode part than the first surface in the first direction.