Embedded Electrode Positioning in Multilayer Electronic Components
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Solution Overview
Problem
Conventional electronic components face challenges in maintaining a predetermined positional relationship between external electrodes and coils, which is crucial for arbitrary electric characteristics, as the formation of external electrodes after the coil can lead to positional deviations due to variations in cut positions or formation processes.
Innovation Solution
The electronic component features a multilayer body with stacked insulator layers, where both the first and second external electrodes are embedded in the lateral surfaces formed by continuous perimeter edges, and are simultaneously formed with the coil conductor layers using photolithography or printing, ensuring precise positional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external electrodes are formed after the coil using separate processes, then the multilayer body can be manufactured, but the positional relationship between external electrodes and coil may deviate from predetermined relationship
Solution Approach 1:
The patent combines the formation of external electrodes and coil into a single photolithography step. The external electrode pattern and coil pattern are formed simultaneously on the same insulator layer using one photomask and one development process, eliminating sequential processing steps. This merging of operations ensures that both structures are created with the same positional reference, guaranteeing precise positional relationship while maintaining manufacturing efficiency.
2Manufacturing precision
If external electrodes and coil are formed in the same step by photolithography, then positional relationship is maintained, but the structure cannot be easily configured for arbitrary electric characteristics
Solution Approach 1:
The patent segments the conductor layer into functionally distinct regions within the same insulator layer. The external electrode pattern and coil pattern are formed as separate conductive regions on the same insulator layer, each with independent electrical functions. This segmentation allows the structure to maintain precise positional relationship while enabling arbitrary electric characteristics through independent design of each segmented region's geometry, material, and connectivity.
3Manufacturing precision
If external electrodes are embedded in lateral surfaces formed by continuous perimeter edges, then positional relationship is maintained, but the electrode shapes must differ
Solution Approach 1:
The patent applies local quality by allowing different regions of the same insulator layer to have different conductor patterns with different shapes and functions. The external electrodes are formed with shapes optimized for their specific electrical connection requirements, while the coil is formed with shapes optimized for inductance characteristics. Each local region's conductor shape is independently optimized for its specific function while maintaining consistent positional relationship through the unified photolithography process.
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 maintains a consistent positional relationship between external electrodes and coils, allowing for arbitrary electric characteristics and improved manufacturing accuracy, enabling the formation of noise filters with adjustable resonant frequencies.
Implementation Method 1
the external conductor layers and the first coil conductor, which are provided to the same insulator layer, are simultaneously formed by photolithography or printing
Data Source
AI summary
In an electronic component, a multilayer body is formed by a plurality of stacked insulator layers. A coil includes at least one coil conductor layer provided on at least one of the insulator layers. External electrodes are embedded in a lateral surface of the multilayer body which is formed by a series of continuous perimeter edges of the plurality of insulator layers, and includes a plurality of stacked external conductor layers provided on the plurality of insulator layers. The external electrodes have different shapes. The external conductor layers and the first coil conductor, which are provided on the same insulator layer, are simultaneously formed by photolithography or printing.