Low-Profile Coil Component With Embedded Electrode Slit Connection
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Solution Overview
Problem
In low-profile coil components, the reduction in magnetic material area affects inductance properties, and existing designs struggle to maintain reliable connections between coils and external electrodes, especially when slit depths are shallow.
Innovation Solution
The design embeds external electrodes within the coil component's body and incorporates protrusions on lead-out portions to ensure reliable electrical connections, even with shallow slits, thereby maintaining effective volume and inductance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the magnetic material area is reduced to achieve a low-profile design, then the thickness of the coil component is reduced, but the inductance properties degrade
Solution Approach 1:
The patent transitions from traditional side-contact external electrodes to top-surface embedded external electrodes. By changing the dimensional arrangement of electrodes from lateral contact to vertical embedding in the body surface, the design achieves reduced thickness while maintaining effective magnetic material area and inductance properties through optimized spatial configuration.
Solution Approach 2:
The external electrodes are embedded within the body structure rather than extending externally. This nesting approach integrates the electrodes into the coil component body, reducing overall thickness while maintaining functional performance through internal placement that preserves magnetic material volume.
2Ease of manufacture
If the slit depth is reduced to simplify manufacturing, then the manufacturing complexity is reduced, but the connection reliability between coil and external electrode deteriorates
Solution Approach 1:
Protrusions are pre-formed on the coil windings before the external electrodes are embedded in the body. This preliminary structuring ensures that when shallower slits are used, the protrusions extend sufficiently to maintain reliable electrical connection between the coil and external electrodes, compensating for reduced slit depth without complicating manufacturing.
3Reliability
If the external electrodes are disposed externally to maintain connection reliability, then the connection reliability is maintained, but the thickness of the coil component increases
Solution Approach 1:
The patent repositions external electrodes from external lateral placement to embedded top-surface placement. This dimensional change allows electrodes to be integrated within the body thickness rather than extending beyond it, reducing overall component thickness while maintaining connection reliability through the protrusion-electrode interface.
Solution Approach 2:
The external electrodes are merged with the body structure through embedding. This integration combines the electrode function within the existing body volume, eliminating the need for separate external electrode extensions and thereby reducing overall component thickness while maintaining functional connectivity.
Data Source
AI summary
According to an aspect of the present disclosure, a coil component includes a body including a first surface and a second surface opposing each other in a first direction, and a slit disposed in the first surface; a coil disposed in the body and including a coil portion having at least one turn, a lead-out portion extending from an outermost turn of the coil portion, and a protrusion extending to the slit; and an external electrode disposed on the slit to be in contact with the protrusion.