Coil Component Terminal Layout for Stable Substrate Soldering
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Solution Overview
Problem
Existing winding coil components face issues with satisfactory soldering due to flattened wire end portions occupying large areas of terminal electrodes, hindering effective connection to mounting substrates, and insulating resin scattering during thermocompression bonding.
Innovation Solution
The coil component design includes flattened wire end portions with controlled orientations and positions, allowing them to traverse terminal electrodes in a diagonal direction, and features slopes on flange portions to facilitate thermocompression bonding, reducing stress concentration and enabling wider substrate mounting areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire end portions are flattened through thermocompression bonding to connect to terminal electrodes, then the electrical connection between wires and terminal electrodes is improved, but the flattened portions occupy large areas of the terminal electrodes and hinder soldering connections to mounting substrates
Solution Approach 1:
The terminal electrode is divided into two distinct functional regions: a first region for wire connection and a second region for substrate mounting. This segmentation allows the flattened wire portions to occupy only the first region, leaving the second region clear for effective soldering operations without interference
Solution Approach 2:
The wire connection function is extracted from the entire terminal electrode surface and concentrated in a specific first region. This extraction creates a dedicated zone for wire attachment while preserving the remaining electrode area for substrate mounting purposes
2Reliability
If insulating resin is applied to wires during thermocompression bonding, then insulation is provided, but the resin scatters on the terminal electrodes and hinders soldering
Solution Approach 1:
The insulating resin application is restricted to only the first region of the terminal electrode where wire connection occurs. This localized application provides necessary insulation at the wire connection point while preventing resin scattering onto the second region, thereby maintaining soldering capability
Solution Approach 2:
Insulation is applied locally only where needed (at the wire connection region) rather than uniformly across the entire terminal electrode. This local quality approach ensures adequate insulation at the connection point while avoiding unnecessary resin deposition that would interfere with soldering operations
3Volume of moving object
If the wire extended direction is optimized for compactness, then the component size is reduced, but the mounting surface area for substrate connection is limited
Solution Approach 1:
The terminal electrode utilizes a two-dimensional surface layout with distinct regional zones rather than a single linear dimension. The first region accommodates wire connections while the second region provides mounting surface area, allowing both functions to coexist without compromising component compactness
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 configuration ensures stable soldering connections, reduces stress concentration, and enhances bending strength, minimizing the risk of cracks and improving the overall mounting process.
Implementation Method 1
The wires are extended from the winding core portion and are connected to the respective terminal electrodes by thermocompression bonding
Data Source
AI summary
A coil component includes a core including a winding core portion and flange portions; wires wound around the winding core portion; and terminal electrodes on the respective flange portions. The wires respectively have flattened portions connected to the terminal electrodes. The flattened portions each have a shape that becomes thinner from the winding core portion toward a tip end of a corresponding one of the wires. When viewed from a side where mounting surfaces are located, a center axis of a part of each of the flattened portions closer to the winding core portion and a center axis of a part of a corresponding one of the flattened portions closer to the tip end extend in different directions. The center axis of the part of each of the flattened portions closer to the tip end extends in a direction parallel to an axial direction.