Inductor Outer Electrode Plating for Low-Profile Environmental Resistance
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Solution Overview
Problem
The formation of outer electrodes on the element body protective film of existing inductors leads to an increase in the external dimensions of the inductor, resulting in deteriorated electrical characteristics.
Innovation Solution
The outer electrode is designed to run on the rim portion of the element body protective film with a gradually thinner thickness, forming multiple plated layers to suppress the rise of the electrode and maintain favorable electrical characteristics while improving environmental resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer electrode is formed to run on the element body protective film, then the environment resistance is improved, but the external dimensions of the inductor increase due to electrode rise
Solution Approach 1:
The protective film is designed with non-uniform thickness, specifically thinner at the rim portion where the outer electrode runs. This local variation in film thickness allows the electrode to be formed on the protective film surface without excessive rise, while still providing adequate protection and improving environment resistance.
Solution Approach 2:
The thickness parameter of the protective film is changed from uniform to graduated/thinner at the rim portion. This parameter modification enables the outer electrode to run on the protective film with reduced rise height, thereby improving environment resistance while controlling external dimensions.
2Reliability
If the outer electrode runs on the element body protective film, then the environment resistance is improved, but the electrical characteristics deteriorate due to restricted element body dimensions
Solution Approach 1:
The protective film thickness is locally optimized at the rim portion to be thinner, allowing the outer electrode to run on the film without excessive rise. This local modification enables the electrode to provide improved environment resistance while minimizing impact on element body dimensions and maintaining electrical characteristics.
Solution Approach 2:
By changing the thickness parameter of the protective film at the rim portion, the design enables the outer electrode to run on the protective film surface with controlled rise height. This parameter optimization allows simultaneous achievement of improved environment resistance and maintained electrical characteristics.
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 design effectively suppresses the rise of the outer electrode, maintaining the inductor's external dimensions and enhancing its electrical and environmental resistance performance.
Implementation Method 1
The outer electrode includes a first plated layer formed on the extended portion and a second plated layer formed on the first plated layer
Data Source
AI summary
An inductor includes a coil conductor including a pair of extended portions; an element body containing a metallic magnetic particle and a first resin and enclosing the coil conductor; an outer electrode connected to one of the extended portions exposed from a surface of the element body; and an element body protective film including an opening at a portion where at least the extended portion is exposed from the surface of the element body, and covering the surface of the element body. The outer electrode includes a first plated layer on the extended portion and a second plated layer on the first plated layer, the first and second plated layers are extended while covering a rim portion of the opening of the element body protective film, and respective end portions of the first plated layer and the second plated layer are in contact with the element body protective film.