Embedded-Wire Inductor Electrodes for Higher Terminal Peel Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inductor technologies face challenges in achieving high peel strength for external terminals, which is crucial for reliable electrical connections and durability.
Innovation Solution
A coil component with a base body containing magnetic particles and resin, where a band-shaped conductive wire is wound and embedded in a core, and an outer electrode is formed by plating on exposed sections, extending into the base body for enhanced joining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plating is performed on the extended portions of the coil conductor to ensure sufficient joining strength, then the joining strength between the coil conductor and outer electrodes is improved, but the peel strength of external terminals is still insufficient
Solution Approach 1:
The outer electrode is extended from a surface-level structure into the base body in the depth dimension. The metal layer extends into the base body at a boundary between the electrode formation section and the base-body protection layer, creating an L-shaped configuration that provides both surface coverage and internal anchoring, thereby significantly improving peel strength
Solution Approach 2:
The metal layer of the outer electrode is nested within the base body structure. The outer electrode is formed not only on the surface but also extends into the base body, creating a nested configuration where the electrode is embedded within the protective encapsulation resin, enhancing the mechanical interlocking and electrical connection
2Ease of manufacture
If the outer electrode is formed only on the exposed portion of the coil conductor, then the manufacturing process is simple, but the peel strength of external terminals is insufficient
Solution Approach 1:
The outer electrode structure is extended from two-dimensional surface plating to three-dimensional configuration by making the metal layer extend into the base body at the boundary region, creating an L-shaped electrode that provides both surface coverage and internal anchoring without significantly complicating the manufacturing process
Solution Approach 2:
The metal layer is selectively extended into the base body at specific boundary regions between the electrode formation section and the base-body protection layer, rather than uniformly throughout. This localized extension provides enhanced peel strength where most needed while maintaining manufacturing efficiency
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
The solution significantly increases the peel strength of external terminals by forming a strong electrical connection between the outer electrode and the base body, ensuring robustness and reliability.
Implementation Method 1
a step of forming an electrode formation section by irradiating an area including an exposed portion at which the surface of the extended section is exposed with laser light to remove the base-body protection layer
Implementation Method 2
a metal layer that is an outer electrode is formed by plating
Data Source
AI summary
An inductor includes a base body including a coil conductor and a core in which the coil conductor is embedded. The coil conductor includes a wound band-shaped conductive wire. The core contains soft magnetic particles and a resin. The base body is rectangular-parallelepiped-shaped and includes a pair of principal faces that are opposite to each other, a pair of end faces that are opposite to each other and adjacent to the principal faces, and a pair of side faces that are opposite to each other and adjacent to the principal faces. A base-body protection layer is on a surface of the base body. The coil conductor includes a wound section and extended sections extending from the wound section. The extended sections have surfaces exposed on the surface of the base body at respective exposed portions on each of which a metal layer that is an outer electrode is formed.