Inductor Outer Electrode R-Chamfered Adhesion
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Solution Overview
Problem
The existing inductors have insufficient adhesion strength to a mounting substrate due to small outer electrode areas, which limits their mounting reliability and efficiency.
Innovation Solution
The inductor design includes a coil, a body made of magnetic powder and resin, a protection layer, and outer electrodes with R-chamfered sections, where the first electrode region is on the bottom surface and the second electrode region is on the end surfaces, enhancing mechanical bonding and adhesion strength through surface roughness and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the outer electrode area is kept small, then the inductor structure remains compact, but the adhesion strength to the mounting substrate becomes insufficient
Solution Approach 1:
The outer electrode is extended from the bottom surface to the end surfaces of the inductor, utilizing the vertical dimension and lateral surfaces to increase the effective bonding area. This dimensional expansion allows the electrode to wrap around and bond to the mounting substrate from multiple directions, significantly improving adhesion strength without increasing the overall footprint of the inductor.
Solution Approach 2:
The outer electrode is divided into multiple regions: a first electrode region on the bottom surface and a second electrode region on the end surfaces. This segmentation allows each region to perform its specific function optimally - the first region provides primary electrical connection while the second region enhances mechanical bonding and adhesion to the substrate through the extended surface area.
2Strength
If the surface roughness of the bottom surface is increased, then the adhesion strength is improved, but the flatness of the mounting surface deteriorates
Solution Approach 1:
The bottom surface is segmented into two distinct zones: a first area with increased surface roughness for enhanced adhesion strength, and a second area that maintains flatness for proper mounting alignment. This spatial segmentation allows the inductor to simultaneously achieve both high bonding strength and good flatness in different regions of the same surface.
Solution Approach 2:
The surface roughness is applied locally to specific regions of the bottom surface where adhesion is most critical, rather than uniformly across the entire surface. This localized treatment ensures that the mounting areas requiring high bonding strength have roughened surfaces, while other areas maintain the flatness needed for proper positioning and alignment during mounting.
Data Source
AI summary
An inductor includes a coil including a winding portion and a lead-out portion, a body constituted by a magnetic member and enclosing the coil, a protection layer disposed on a surface of the body, and an outer electrode. The body has a bottom surface, a top surface, two end surfaces, two side surfaces, and first and second R-chamfered sections. The outer electrode includes first and second electrode regions. The first electrode region is located on the bottom surface and is electrically connected to the lead-out portion. The second electrode region is located on the protection layer on each end surface. The surface roughness of part of the bottom surface where the first electrode region is disposed is greater than that of the protection layer on each of the end surfaces where the second electrode region is disposed.