Electronic Component Side Parts Prevent Coil Exposure
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Solution Overview
Problem
Existing inductor manufacturing methods face challenges in preventing exposure of internal coil patterns and achieving high inductance, often resulting in electrode exposure defects and increased delamination rates due to cutting deviations and high current stresses.
Innovation Solution
The electronic component design includes a magnetic body with internal coil patterns exposed to side surfaces and covered by side parts, which are formed on the side surfaces to prevent exposure and increase the area of the coil patterns, thereby enhancing inductance without needing additional margin parts in the magnetic body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If internal coil patterns are exposed to side surfaces to increase area and inductance, then inductance is improved, but electrode exposure defects occur
Solution Approach 1:
The side surface is segmented into different functional zones: coil pattern exposure areas for inductance enhancement and side part coverage areas for defect prevention. The side parts are formed to cover specific portions of the side surfaces where electrode exposure defects would occur, while allowing coil pattern portions to remain exposed for inductance improvement.
2Ease of operation
If cutting is performed to expose lead portions to end surfaces, then lead portions are exposed, but cutting deviations cause electrode exposure defects
Solution Approach 1:
Side parts are formed on the side surfaces before final cutting operations. This preliminary action creates a protective structure that compensates for potential cutting deviations, ensuring that even if cutting precision varies, the side parts will cover any exposed electrode areas that would otherwise create defects.
3Reliability
If margin parts are added to magnetic body to prevent exposure, then exposure defects are prevented, but device complexity increases
Solution Approach 1:
Instead of adding margin parts in the planar dimensions of the magnetic body, the solution moves to a third dimension by forming side parts on the side surfaces. This vertical/dimensional approach prevents electrode exposure defects without increasing the planar complexity or requiring additional margin structures within the magnetic body plane.
Data Source
AI summary
An electronic component includes a magnetic body having first and second end surfaces opposing each other and first and second side surfaces connected to the first and second end surfaces, and first and second internal coil patterns disposed in the magnetic body and including coil pattern portions having a spiral shape and lead portions connected to ends of the coil pattern portions and exposed to one surfaces of the magnetic body, respectively. The coil pattern portions are exposed to the first and second side surfaces, and first and second side parts are disposed on the first and second side surfaces. A manufacturing method therefore is presented.