Coil Component Green Sheet Protrusions for Stacking Alignment
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Solution Overview
Problem
Existing methods for manufacturing electronic components face challenges in preventing stacking misalignment of sheets in a stacked body during the manufacturing process.
Innovation Solution
The method involves forming sheets with a conductor layer having protrusions that protrude from an insulating layer, allowing for an anchor effect that restricts movement and alignment during stacking, thereby suppressing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sheet stacking method is used, then manufacturing process is simple, but stacking misalignment occurs between sheets
Solution Approach 1:
Protrusions are formed on the conductor layers during the sheet manufacturing process, creating alignment features in advance. When sheets are stacked, these pre-formed protrusions automatically engage with corresponding features on adjacent sheets, ensuring precise alignment without requiring complex alignment procedures during assembly.
Solution Approach 2:
The alignment problem is solved by adding a vertical dimension feature (protrusions extending from the sheet surface) to the otherwise planar sheets. This third-dimensional feature enables mechanical interlocking between stacked sheets, transforming a two-dimensional alignment problem into a three-dimensional solution that prevents misalignment in the stacking direction.
2Stability of the object's composition
If sheets are stacked without anchoring features, then manufacturing process is simple, but sheets move relative to each other causing misalignment
Solution Approach 1:
The conductor layer is segmented into multiple regions with different height positions, creating distinct protrusion features. This segmentation allows specific portions of the conductor layer to serve as anchoring protrusions that engage with corresponding features on adjacent sheets, providing stable positioning while maintaining the overall integrity of the conductor pattern.
Solution Approach 2:
Different regions of the conductor layer are given different local properties - some regions form protrusions that extend beyond the insulating layer surface while other regions remain flush. These localized protrusion features provide anchoring functionality at specific critical positions without requiring the entire conductor layer to be modified, thus maintaining ease of manufacture while achieving 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
This approach effectively suppresses stacking misalignment, enhances bonding strength, and improves the structural integrity of the stacked body.
Implementation Method 1
the protrusion of the first conductor layer bites into another sheet. Therefore, in the method for manufacturing an electronic component, the movement of the first sheet in a direction (direction along the insulating layer of the sheet) orthogonal to a stacking direction with respect to another sheet can be restricted by an anchor effect.
Data Source
AI summary
In a method for manufacturing a coil component, in a step of forming a plurality of green sheets, a process of forming, using an insulating paste, an element-body pattern having a defective portion and a process of forming, using a conductor paste, a conductor pattern having protrusions protruding from a surface of the element-body pattern in the defective portion of the element-body pattern are performed to form at least one first green sheet of the plurality of green sheets, the conductor pattern includes a plurality of regions A having different height positions with respect to the surface of the element-body pattern, and the protrusions are formed in the conductor pattern by the region protruding from the surface of the element-body pattern in the plurality of regions.