Coil Component Support Electrode Warpage Control
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Solution Overview
Problem
The miniaturization of electronic devices has led to challenges in precisely controlling thin-film type coil substrates due to warpage and misalignment during the laminating process of magnetic composite sheets, resulting in position errors of the coil substrate.
Innovation Solution
A coil component design featuring a body with internal insulating layers and a coil portion, supported by a support electrode, which includes external and connection electrodes to stabilize the coil structure and prevent deformation during the laminating process, thereby reducing position errors and enhancing bonding forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil substrate is thinned to achieve miniaturization, then the size and weight of the coil component are reduced, but the coil substrate becomes increasingly difficult to control due to warpage and misalignment during the laminating process
Solution Approach 1:
The support electrode is formed on the coil substrate before the laminating process of the magnetic composite sheet. This preliminary formation of the support electrode provides structural reinforcement that prevents warpage and maintains position control during the subsequent laminating process, allowing thin substrates to be manufactured with high precision
Solution Approach 2:
The invention uses a composite structure combining the thin coil substrate with the support electrode and magnetic composite sheet. This composite construction provides the necessary mechanical strength and dimensional stability while maintaining the overall miniaturization, as the support electrode and magnetic sheet work together to prevent substrate deformation
2Weight of moving object
If the coil substrate is thinned to reduce component size, then the coil component becomes smaller and lighter, but position error of the coil portion increases due to warpage during lamination
Solution Approach 1:
The support electrode is formed on the coil substrate before the laminating process to provide preliminary structural support. This prevents warpage during lamination and ensures the coil portion maintains its intended position, reducing position error while allowing the substrate to be thinned for weight reduction
Solution Approach 2:
The support electrode is strategically positioned and configured to provide localized reinforcement where needed. The electrode pattern and distribution are optimized to prevent warpage in critical areas while maintaining overall substrate thinness, thus reducing position error without adding unnecessary weight
3Volume of moving object
If the coil substrate is thinned to achieve miniaturization, then the coil component can be made smaller and more compact, but the bonding force and structural stability are compromised
Solution Approach 1:
The invention creates a composite structure where the thin coil substrate is combined with the support electrode and magnetic composite sheet. This composite construction compensates for the reduced bonding force of the thinned substrate, as the support electrode and magnetic sheet work together to provide the necessary structural stability and bonding strength
Solution Approach 2:
The support electrode is formed on the coil substrate before lamination to create a reinforced bonding interface. This preliminary reinforcement ensures that even though the substrate is thinned, the bonding force between the substrate and magnetic composite sheet is sufficient to maintain structural stability
Data Source
AI summary
A coil component includes a body having one surface and another surface opposing each other in one direction, an internal insulating layer embedded in the body, and a coil portion disposed on the internal insulating layer and forming at least one turn. First and second external electrodes are disposed on the one surface of the body to be spaced apart from each other, and first and second connection electrodes respectively penetrate through the body to connect the coil portion and the first and second external electrodes to each other. A support electrode extends from the coil portion to be exposed to the other surface of the body to support the coil portion and the internal insulating layer.