Inductor External Electrode Overlap Insulating Layer
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Solution Overview
Problem
Miniaturized inductors face challenges in maintaining bonding strength and preventing short circuits due to insulating layers, which reduce the area of contact between external electrodes and the body, leading to instability during mounting.
Innovation Solution
The external electrodes are designed to overlap the insulating layer on the body's surfaces, ensuring a stable connection and improved bonding strength by extending to the upper, lower, and side surfaces while maintaining a specific ratio of overlapping to non-overlapping lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is formed on the body of the inductor to prevent short circuits, then short circuit prevention is improved, but bonding strength between external electrodes and the body decreases
Solution Approach 1:
The insulating layer is selectively formed only on specific regions of the inductor body surface where short circuit prevention is needed, rather than covering the entire surface. This allows the external electrodes to maintain direct contact with the body in non-insulated regions, preserving bonding strength while still providing insulation where required.
Solution Approach 2:
The surface of the inductor body is divided into insulated regions and non-insulated regions. The insulating layer is applied segmentally to specific areas, allowing different portions of the body to serve different functions - some areas provide electrical insulation while others maintain electrical contact and bonding with external electrodes.
2Productivity
If the inductor is miniaturized to reduce size, then productivity and integration are improved, but the risk of short circuits increases
Solution Approach 1:
In miniaturized inductors, the insulating layer is applied locally to critical regions where short circuit risk is highest, such as areas close to other conductive elements or regions with high electric field concentration. This targeted approach provides necessary insulation without significantly increasing the overall size of the component.
Solution Approach 2:
The insulating layer is applied in specific dimensional regions of the miniaturized inductor, using selective spatial positioning to provide insulation only where needed. This allows the compact design to maintain reliability without requiring additional space for insulation materials.
3Reliability
If an insulating layer is formed on the body, then short circuit prevention is improved, but mounting stability decreases
Solution Approach 1:
The insulating layer is formed only in regions where short circuit prevention is critical, while leaving other regions exposed for stable mounting and electrical connection. This selective insulation maintains the mechanical and electrical stability required for reliable mounting while still providing protection against short circuits in vulnerable areas.
Data Source
AI summary
An electronic component includes a body including internal electrodes; an insulating layer disposed on side surfaces of the body and at least one of an upper surface of the body and a lower surface of the body; and an external electrode disposed on an end surface of the body and connected to the internal electrodes. The external electrode extends to at least one of the upper surface of the body, the lower surface of the body, and the side surfaces of the body, and partially overlaps the insulating layer.