Recessed Coil Component Mounting for Underfill Entry
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Solution Overview
Problem
Existing coil components with embedded coils in magnetic element bodies have exposed conductor posts that prevent underfill materials from entering between the mounting surface and the circuit board, affecting mounting reliability.
Innovation Solution
A coil component design with a recessed surface on the magnetic element body, allowing the conductor posts to protrude slightly, creating a space for underfill materials to enter, and a manufacturing method involving steps to form and embed the coil and conductor posts within the magnetic element body, followed by surface grinding and pressure application to achieve the recess.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor post is exposed from the mounting surface, then the electrical connection is ensured, but the underfill material cannot enter between the mounting surface and the circuit board
Solution Approach 1:
The patent introduces a recess dimension on the mounting surface, creating a stepped structure where the element body surface is lower than the conductor post surface. This dimensional change allows the underfill material to flow into the recess area and reach the interface between the coil component and circuit board, while the conductor post remains exposed for electrical connection.
2Ease of manufacture
If the element body surface is made flat, then the manufacturing process is simplified, but the underfill material entry is prevented
Solution Approach 1:
The mounting surface is segmented into two distinct levels: the element body surface forming a recess area, and the conductor post surface protruding above it. This segmentation allows the flat element body surface to be manufactured easily while the recess structure enables underfill material entry, resolving the contradiction between manufacturing simplicity and mounting reliability.
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
Enhances mounting reliability by allowing underfill materials to easily enter between the coil component and the circuit board, improving the structural integrity and reliability of the assembly.
Implementation Method 1
a step of grinding the surface of the element body so as to expose the other end of the conductor post therefrom
Implementation Method 2
a step of applying pressure to the element body such that the surface of the element body is recessed from the surface of the conductor post
Data Source
AI summary
Disclosed herein is a coil component that includes an element body having a mounting surface, a coil part embedded in the element body, and a first conductor post embedded in the element body. The first conductor post has a first end connected to the coil part and a second end exposed from the mounting surface. A surface of the element body on the mounting surface side has a recess from a surface of the first conductor post.