Coil Component Electrode Layout for Compact Short-Circuit Isolation
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Solution Overview
Problem
Conventional coil components face challenges in miniaturization due to thick external electrodes, leading to increased overall size and potential short-circuits when mounted on a board, as they are often formed on opposing surfaces, which can result in contact with adjacent components.
Innovation Solution
A coil component design featuring a body with opposing end surfaces, lead-out patterns, slit portions, and external electrodes spaced apart, with surface and slit insulating layers, including silicon dioxide and aluminum oxide, to reduce size and prevent short-circuits while increasing the effective volume of magnetic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external electrodes are formed on opposing surfaces of the body, then electrical connection is achieved, but the overall size increases and short-circuit risk increases
Solution Approach 1:
The patent transitions from forming external electrodes on opposing surfaces (2D surface arrangement) to forming lead-out patterns within the body thickness direction (3D internal arrangement). The electrodes are now positioned on the same surface but connected through internal lead-out patterns, changing the spatial dimension of electrode arrangement to reduce overall component size while maintaining electrical connection functionality.
Solution Approach 2:
The lead-out patterns are embedded within the body structure, with the external electrodes nested on the surface and connected through the internal lead-out patterns. This nesting approach allows the electrical connection function to be integrated within the body volume rather than extending externally, reducing the overall size while maintaining reliability.
2Reliability
If external electrodes are made thicker for better connection, then coupling reliability improves, but the overall size increases
Solution Approach 1:
The patent moves the electrode thickness dimension from the lateral direction (affecting overall size) to the thickness direction of the body. The lead-out patterns provide adequate connection area within the body thickness, allowing thin external electrodes that do not increase overall component dimensions while maintaining coupling reliability through sufficient internal connection area.
3Reliability
If more magnetic material is used to increase effective volume, then inductance performance improves, but the component size increases
Solution Approach 1:
The patent utilizes the thickness direction of the body to arrange lead-out patterns and magnetic material, maximizing the use of available volume. By forming lead-out patterns within the body thickness rather than extending externally, the design achieves higher effective magnetic material volume within the same footprint dimensions, improving inductance performance without increasing overall component size.
Data Source
AI summary
A coil component includes a body having one surface, and one end surface and the other end surface connected to the one surface and opposing each other; a coil portion including lead-out patterns within the body; slit portions respectively disposed in an edge portion between the one end surface and the one surface of the body and an edge portion between the other end surface and the one surface of the body to expose the lead-out patterns; external electrodes disposed to be spaced apart from each other on the one surface and respectively extending to the slit portions to be connected to the lead-out patterns; and surface insulating layers, respectively disposed on the one end surface and the other end surface of the body. The surface insulating layers include a first insulating thin film including silicon dioxide (SiO2), and a second insulating thin film including aluminum oxide (Al2O3).