Coil Component Electrode Layout for Selective Surface Insulation
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Solution Overview
Problem
The miniaturization of coil components is limited by the thickness of the insulation layer required for external electrodes, which increases the component's dimensions and affects performance.
Innovation Solution
A coil component design featuring a magnetic base body with external electrodes that protrude beyond an insulation layer, where the insulation layer covers only areas excluding the electrodes, allowing for reduced dimensions and improved performance by minimizing the insulation layer's thickness and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation layer is provided on the component body to ensure electrical insulation, then electrical insulation is improved, but the external dimensions of the coil component increase
Solution Approach 1:
The insulation layer is applied selectively only to specific areas of the component body surface that require insulation, rather than covering the entire surface. This localized approach provides necessary electrical insulation while minimizing the increase in external dimensions of the coil component.
2Length of stationary object
If the external dimensions are fixed, then the component size is reduced, but the component body dimensions must be reduced which lowers coil component performance
Solution Approach 1:
By applying insulation locally only where needed rather than uniformly across the entire component body, the design allows the magnetic base body to maintain its optimal dimensions for performance while still providing necessary insulation. This selective insulation approach enables fixed external dimensions without compromising the coil component's electromagnetic performance.
3Reliability
If the insulation layer thickness is increased to ensure adequate insulation, then electrical insulation is improved, but the component dimensions increase
Solution Approach 1:
The insulation layer is applied only to specific localized areas where electrical insulation is required, rather than covering the entire component body. This approach provides adequate insulation protection at the necessary locations while minimizing the overall volume increase of the coil component.
Data Source
AI summary
A coil component includes a magnetic base body containing a magnetic metal material and having a first surface; a conductor disposed inside the magnetic base body; external electrodes electrically connected to the conductor and extending along the first surface of the magnetic base body, each of the external electrodes having a first electrode portion embedded in the magnetic base body and a second electrode portion exposed from the magnetic base body; and an insulation layer covering an area of the first surface that excludes areas on which the external electrodes are disposed.