Coil Component Via Structure for Magnetic Volume and Bonding
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Solution Overview
Problem
Existing coil components face challenges in optimizing the effective volume of magnetic material and preventing delamination between the coil portion and the body.
Innovation Solution
A coil component design featuring a body with a coil portion, external electrodes on a first surface, and connection vias that connect the external electrodes to the lead-out pattern, where the end surface areas of the connection vias differ between the lower and upper portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external electrodes are disposed on the surface of the coil component, then the coil component can be electrically connected to external circuits, but the effective volume of magnetic material is reduced due to the space occupied by electrodes
Solution Approach 1:
The patent transitions from a conventional single-surface electrode arrangement to a multi-dimensional electrode configuration by disposing external electrodes on both the upper and lower surfaces of the coil component. This dimensional change allows electrical connections to be established without occupying excessive space within the magnetic material volume, thereby resolving the contradiction between connection reliability and magnetic material volume.
Solution Approach 2:
The patent employs connection vias that are integrated within and nested in the magnetic material body to connect the external electrodes to the coil portion. These vias are strategically positioned and sized to minimize displacement of magnetic material while maintaining reliable electrical connectivity, thus preserving the effective volume of magnetic material.
2Adaptability or versatility
If the coil portion and body are formed from different materials, then manufacturing flexibility is improved, but cracks or delaminations may occur between the coil and the body
Solution Approach 1:
The patent introduces connection vias as intermediary elements between the coil portion and the external electrodes. These vias are formed within the magnetic material body and provide a gradual transition zone that accommodates the interface between different materials, reducing stress concentration and preventing delamination while maintaining the flexibility to use different materials for the coil and body.
3Reliability
If connection vias are used to connect external electrodes to the lead-out pattern, then electrical connectivity is achieved, but the bonding force between the body and connection vias may be insufficient leading to delamination
Solution Approach 1:
The patent optimizes the geometric parameters of the connection vias, including their diameter, length, and positioning within the magnetic material body. By carefully controlling these parameters, the bonding surface area between the vias and the magnetic material is maximized, ensuring sufficient bonding force to prevent delamination while maintaining effective electrical connectivity.
Data Source
AI summary
A coil component includes a body; a coil portion disposed in the body and including a lead-out pattern; an external electrode disposed on a first surface of the body; and a plurality of connection vias disposed in the body, connecting the external electrode to the lead-out pattern, and integrated with each other, wherein, in each of the plurality of connection vias, a size of an end surface area of a lower portion adjacent to the external electrode is different from a size of an end surface area of an upper portion adjacent to the lead-out pattern.