Multilayer Coil Lead-Out Structure for Stable Electrode Contact
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Solution Overview
Problem
The contact area between the lead-out portion and the external electrode in multilayer inductors decreases during sintering, leading to degraded direct current resistance and structural stability.
Innovation Solution
A coil electronic component with a laminate structure featuring a coil pattern and a lead-out pattern composed of multiple metal layers, where the second metal layer is thicker and covers the first metal layer, increasing the contact area and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead-out portion is sintered with the external electrode, then the inductor is formed, but the contact area between the lead-out portion and external electrode decreases
Solution Approach 1:
The patent transitions from a single-layer lead-out structure to a multi-layer lead-out structure. The lead-out portion comprises a first metal layer and a second metal layer stacked in different dimensions, increasing the contact area with the external electrode in the vertical dimension while maintaining the horizontal footprint.
Solution Approach 2:
The lead-out portion uses composite material structure with at least two different metal layers. The first metal layer and second metal layer have different material compositions, creating a composite structure that maintains structural integrity while providing sufficient contact area after sintering.
2Manufacturing precision
If the contact area decreases during sintering, then the inductor structure is formed, but the direct current resistance degrades
Solution Approach 1:
By stacking multiple metal layers vertically, the patent increases the contact area in the vertical dimension. This compensates for the contact area reduction that occurs during sintering, thereby maintaining low direct current resistance while achieving proper inductor structure formation.
Solution Approach 2:
The patent changes the structural parameters of the lead-out portion by introducing multiple metal layers with different thicknesses and materials. This parameter change ensures that even after sintering causes contact area reduction, the multi-layer structure provides sufficient total contact area to maintain acceptable direct current resistance.
3Manufacturing precision
If the contact area decreases during sintering, then the inductor is formed, but the structural stability degrades
Solution Approach 1:
The use of composite material structure with multiple metal layers provides both mechanical strength and electrical conductivity. The different metal layers work together to maintain structural stability during and after sintering, preventing degradation while enabling proper inductor formation.
Solution Approach 2:
The multi-layer vertical structure distributes mechanical stresses across multiple layers, enhancing structural stability. This dimensional approach provides redundancy, so that even if one layer experiences contact area reduction, the overall structure maintains stability.
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
The solution enhances direct current resistance and structural stability by ensuring a sufficient contact area between the lead-out pattern and external electrodes, improving the overall performance of the coil electronic component.
Implementation Method 1
A coil electronic component with a laminate structure featuring a coil pattern and a lead-out pattern composed of multiple metal layers
Data Source
AI summary
A coil electronic component is provided, the coil electronic component including a body having a laminate structure formed of a plurality of conductor patterns disposed therein, and including an insulating layer disposed between the plurality of conductor patterns, and an external electrode disposed externally of the body. Portions of the plurality of conductor patterns include a coil pattern and a lead-out pattern connecting the coil pattern and the external electrode, the lead-out pattern includes a first metal layer and a second metal layer disposed on the first metal layer, and a pore density of the first metal layer is higher than a pore density of the second metal layer.