Composite Electrode Structure for Miniaturized Electrical Components
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Solution Overview
Problem
As electronic components become smaller, conventional electrode structures face challenges in size reduction and reliability, with conventional electroplating causing variability in electrical performance and potential short circuits due to material spread during chemical plating.
Innovation Solution
A novel electrode structure comprising an inner metal layer and an outer metal layer, where the inner metal layer is embedded within the body of the electrical component, with a saw-tooth structure and an adhesive layer for secure connection, allowing for reduced size and improved reliability by using materials like copper, gold, or resin-coated copper foils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electroplating is used to create electrodes, then the electrode can be formed, but the resistance varies significantly degrading electrical performance
Solution Approach 1:
The patent uses a composite electrode structure consisting of an inner metal layer (copper or aluminum) combined with an outer metal layer (tin, nickel, or other conductive materials). This composite structure combines the high conductivity of the inner layer with the reliability and solderability of the outer layer, achieving consistent electrical performance while avoiding the variability problems of conventional electroplating.
Solution Approach 2:
The electrode structure applies different material properties to different layers: the inner layer provides high electrical conductivity, while the outer layer provides reliable soldering surfaces and corrosion resistance. This local differentiation of material qualities allows each layer to optimize its specific function, resulting in overall improved reliability and manufacturing precision.
2Reliability
If chemical plating is used to create electrodes, then the electrode can be formed, but the plating material spreads into unwanted areas causing short circuits
Solution Approach 1:
The electrode is divided into distinct inner and outer layers with clearly defined boundaries. The inner metal layer is completely enclosed by the outer metal layer, creating segmented regions that prevent material spread. This segmentation ensures that plating materials remain confined to their designated areas, eliminating the short circuit problem.
Solution Approach 2:
The inner metal layer is nested within the outer metal layer, creating a contained structure where the inner layer is completely surrounded by the outer layer. This nesting arrangement physically constrains the plating materials, preventing them from spreading into unwanted areas while maintaining reliable electrical connections.
3Reliability
If lead frame is used as electrode, then electrical connection can be established, but the component size becomes too large for small footprint applications
Solution Approach 1:
The invention extracts the essential electrode function from the bulky lead frame structure and implements it directly on the component terminals through the inner and outer metal layers. This extraction eliminates the need for separate lead frame structures, significantly reducing the component footprint while maintaining reliable electrical connections for surface-mount technology.
4Area of stationary object
If electrode size is reduced for smaller components, then space is saved, but mechanical and electrical reliability deteriorates
Solution Approach 1:
The composite electrode structure uses an inner metal layer for electrical conductivity combined with an outer metal layer for mechanical strength and soldering reliability. This composite approach allows the electrode to maintain small dimensions while preserving both mechanical and electrical reliability through the synergistic properties of the layered material structure.
Solution Approach 2:
The electrode structure employs curved and rounded transitions between layers, particularly at the interfaces between inner and outer metal layers. These curved transitions reduce stress concentration points, enhancing mechanical reliability while maintaining compact dimensions. The smooth transitions prevent sharp corners that would be prone to failure in miniaturized components.
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 solution enables a compact and reliable electrode structure that effectively connects electrical components to circuit boards, enhancing mechanical and electrical reliability while minimizing space requirements and reducing the risk of short circuits.
Implementation Method 1
an adhesive layer between the inner metal layer and the body surface
Implementation Method 2
conventional electroplating may vary very much, which degrades electrical performance
Data Source
AI summary
An electrical component is disclosed, wherein the electrical component comprises: a body and an electrode structure disposed on a first surface of the body, wherein the electrode structure comprises an inner metal layer and an outer metal layer, wherein a terminal of a conductive element of the electrical component is disposed between the inner metal layer and the outer metal layer, wherein the terminal of the conductive element of the electrical component is electrically connected to the inner metal layer and the outer metal layer for electrically connecting with an external circuit.