Inductor with Coating-Free Conductor Ends for Plating Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing method of inductors faces productivity issues due to the separation of plating formed on the surface of the base body and the conductor, which requires thickening of plating to integrate, leading to decreased productivity.
Innovation Solution
The inductor design includes a conductor with a coating layer-free end portion of the extended portion, allowing direct contact with the magnetic body, facilitating easy integration of plating without thickening, and an outer electrode connected to this portion, enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer surrounds the cross section of the conductor in the exposed portion, then the conductor is protected, but the plating formed on the base body surface and the plating formed on the conductor are separated, requiring thickening to integrate and decreasing productivity
Solution Approach 1:
The coating layer is selectively removed from the exposed portion of the extended portion where plating integration is needed, while maintaining the coating layer in other portions for protection. This local modification allows plating to directly contact the conductor surface in the exposed portion, enabling easy integration between base body plating and conductor plating without thickening, thereby resolving the contradiction between conductor protection and plating integration efficiency
2Reliability
If plating is thickened to integrate the plating on base body surface and conductor, then integration is achieved, but productivity decreases
Solution Approach 1:
The coating layer is removed in advance from the exposed portion of the extended portion before the plating process. This preliminary action ensures that the conductor surface is exposed and ready for direct plating contact, allowing thin plating to integrate easily between the base body and conductor without requiring thickening, thus maintaining high productivity while achieving reliable plating integration
Data Source
AI summary
An inductor includes a coil that is constituted by a conductor having a coating layer and includes a winding portion where the conductor is wound and an extended portion extended from the winding portion, a base body that envelops the coil and is constituted by a magnetic body containing magnetic powder and resin, and an outer electrode that is arranged on a surface of the base body and connected to the extended portion. The extended portion of the coil includes a conductor portion that does not have the coating layer in an end portion of the extended portion, and the conductor portion includes a first region connected to the outer electrode and a second region in contact with the magnetic body.