Inductor Terminal Electrode Adhesion Design
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Solution Overview
Problem
The challenge is to develop an inductor component that is smaller in size while maintaining strong adhesion to a circuit board to prevent electrode separation, which is a common issue with reduced terminal electrode areas in miniaturized electronic devices.
Innovation Solution
The inductor component features a core with terminal electrodes that include a bottom electrode section, side electrode sections, and an end electrode section, where the end electrode section has a greater surface area due to its design, with the end electrode section being higher at the central portion than at the end portions, and the side electrode sections having varying inclinations, all of which are connected by a wire wound around the core, enhancing adhesion and reducing the risk of wire breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inductor component is reduced in size, then the mounting area in electronic devices is improved, but the terminal electrode area is reduced causing electrode separation
Solution Approach 1:
The terminal electrode is designed with a three-dimensional structure including a bottom electrode section, side electrode section, and end electrode section. The end electrode section extends beyond the side electrode section to create an overlapping region, effectively utilizing vertical and lateral dimensions to increase the electrode contact area without increasing the horizontal footprint of the component.
Solution Approach 2:
The underlying layer thickness is varied across different regions of the terminal electrode. The maximum thickness of the underlying layer on the end face is greater than on the bottom face, providing enhanced adhesion locally where the end electrode section contacts the circuit board, thereby preventing electrode separation in critical areas.
2Reliability
If the end electrode section is made higher at the central portion, then the surface area and adhesion are improved, but the device complexity increases
Solution Approach 1:
The end electrode section features a curved top surface where the central portion is higher than the end portions, creating a convex shape. This curvature increases the surface area available for adhesion to the circuit board while maintaining a compact structure that does not significantly increase manufacturing complexity.
Data Source
AI summary
An inductor component includes a core including a substantially column-shaped shaft and a support formed on an end portion of the shaft and a terminal electrode formed on the support. The terminal electrode includes an underlying layer on a surface of the support. A maximum thickness of the underlying layer on an end face of the support is greater than a maximum thickness of the underlying layer on a bottom face of the support.