Miniature Coil Terminal Electrode Curvature Against Stress Separation
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Solution Overview
Problem
As the size of coil components decreases, the terminal electrodes become smaller, leading to increased separation from the core, affecting the characteristics of the coil component, particularly due to stress concentration at corner edges under external forces like thermal expansion or vibration.
Innovation Solution
The coil component features a convex curve shape for its terminal electrodes, reducing stress concentration and preventing separation from the core by distributing stress evenly, and a method of manufacturing that forms these electrodes with a convex curve during the electrode formation step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the coil component is decreased, then the miniaturization of the component is achieved, but the terminal electrode area decreases leading to stress concentration and separation from the core
Solution Approach 1:
The terminal electrode is designed with a convex curved outer edge instead of sharp corners. This curvature distributes stress evenly along the electrode perimeter, preventing stress concentration at corners that would lead to separation from the core during thermal expansion or vibration, thus maintaining attachment reliability in miniaturized components
2Area of stationary object
If the terminal electrode area is decreased, then the component size is reduced, but stress concentrates at the corners causing separation from the core
Solution Approach 1:
By forming the outer edge of the terminal electrode with a convex curve, the design eliminates sharp corners where stress would concentrate. The curved geometry redistributes mechanical stress uniformly across the electrode perimeter, enhancing stress resistance even when the electrode area is reduced for miniaturization
Data Source
AI summary
A coil component includes a core including a winding core portion and a first flange portion, a first wire and a second wire that are wound around the winding core portion in the same direction, and a first terminal electrode that is disposed on the first flange portion and that is connected to a first end portion of the first wire. The shape of an outer edge of the first terminal electrode includes a convex curve.