Miniature Coil Component Electrode Structure for Stronger Solder Fixing
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Solution Overview
Problem
Conventional coil components face a challenge in maintaining a strong fixing force between the coil and the mounting substrate when reduced in size, due to a decrease in the adhering amount of mounting solder, leading to lower fixing forces.
Innovation Solution
The coil component design includes a core with a winding core part, flange parts, and electrode parts, where the outer-surface-side base electrode extends from the lower-surface-side base electrode, forming a fillet with mounting solder, and a metal coating film improves solder wettability and corrosion resistance, ensuring a strong fixing force while allowing for size reduction and low-cost, high-freedom design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coil component is reduced in size, then the productivity and design flexibility are improved, but the adhering amount of mounting solder is reduced, leading to lower fixing force
Solution Approach 1:
The electrode part extends in the thickness direction of the flange part, creating a multi-dimensional structure. This vertical extension increases the solder adhering area without increasing the planar footprint, thus maintaining fixing force while enabling size reduction and improving design flexibility.
Solution Approach 2:
The electrode part changes its geometric parameters by extending in the thickness direction with a controlled aspect ratio. This parameter change increases the effective solder adhering area while maintaining compatibility with reduced component sizes, resolving the contradiction between size reduction and fixing force maintenance.
2Device complexity
If the coil component is reduced in size, then the device complexity is reduced, but the adhering amount of mounting solder is reduced, leading to lower fixing force
Solution Approach 1:
By extending the electrode part in the thickness direction rather than increasing planar dimensions, the invention increases solder adhering area without increasing overall component size. This resolves the contradiction between reducing device complexity and maintaining fixing force.
Solution Approach 2:
The electrode part functions as a thin film structure extending in the thickness direction, providing increased adhering surface area within a compact form factor, thus maintaining fixing force while keeping the component small and simple.
3Manufacturing precision
If the outer-surface-side base electrode is made as a metal film, then the manufacturing precision is improved and mounting area influence is reduced, but the strength and impact resistance are reduced
Solution Approach 1:
The electrode part is segmented into two distinct materials: a sintered body for the lower-surface-side base electrode providing strength and impact resistance, and a metal film for the outer-surface-side base electrode providing manufacturing precision and thin profile. This segmentation resolves the contradiction between strength and manufacturing precision.
Solution Approach 2:
Different regions of the electrode part have different material qualities: the lower-surface-side uses a sintered body with high strength for mechanical support, while the outer-surface-side uses a thin metal film for precise manufacturing and reduced mounting area influence. This local quality differentiation resolves the contradiction.
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 configuration enhances the fixing force between the coil component and the substrate, maintaining reliability and ease of manufacturing even at reduced sizes, with improved solder wettability and corrosion resistance.
Implementation Method 1
a fillet can be formed due to wetting of a mounting solder occurring from the lower surface along the outer surface at the time of mounting, so that a fixing force is increased between the coil component and a mounting substrate
Implementation Method 2
the first electrode part includes a metal coating film covering the lower-surface-side base electrode and the outer-surface-side base electrode
Data Source
AI summary
A coil component comprising a core including a winding core having a shape extending in a constant direction, a first flange disposed at a first end in an extending direction of the winding core, and a second flange disposed at a second end in the extending direction of the winding core; first and second electrodes disposed on the first flange; third and fourth electrodes disposed on the second flange; and a coil including a first wire wound around the winding core and electrically connected to the first and third electrodes, and a second wire electrically connected to the second and fourth electrodes. The first and second flanges each have an inner surface facing the winding core, an outer surface facing toward the side opposite to the inner surface, a lower surface connecting the inner and outer surfaces, and an upper surface facing the side opposite to the lower surface.