Inductor Flat Portion Insulating Coating Removal
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Solution Overview
Problem
Existing inductors face connection failures between the coil and outer electrodes due to residue and groove formation during the removal of insulating coatings, which requires thicker plated layers and limits productivity.
Innovation Solution
The inductor design features a coil with insulating coatings that expose flat portions and covered portions, allowing for electrical connection to outer electrodes without residue or groove formation, even with thin plated layers, and includes a magnetic body with metal magnetic substances that improve adhesion and growth of the plated layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating coating is removed by a laser or the like to connect the outer electrode and the end portion of the lead-out portion, then electrical connection is achieved, but a residue of the insulating coating may be generated or the insulating coating may be removed more than necessary forming a groove
Solution Approach 1:
The patent applies preliminary action by forming a flat portion on the end portion of the lead-out portion before the insulating coating removal process. This flat portion serves as a predetermined preparation that ensures proper laser irradiation and prevents excessive removal or residue formation. The flat portion is created by mechanically processing the end portion to expose the conductor wire surface in a controlled manner, which then guides the subsequent laser removal process to achieve precise insulating coating removal without damaging the underlying conductor wire or creating grooves.
2Reliability
If a thicker plated layer is formed to ensure electrical connection when discontinuous portion exists, then connection reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies preliminary action by creating a flat portion on the end portion of the lead-out portion before plating. This flat portion ensures that the plated layer can be formed uniformly with adequate thickness without requiring excessive plating material. The flat portion provides a stable base that promotes consistent plating deposition, eliminating the need for thicker plated layers to compensate for discontinuities. This preliminary preparation allows for controlled, uniform plating that achieves reliable electrical connection with optimized material usage.
3Ease of manufacture
If the insulating coating is removed more than necessary forming a groove, then the groove may be filled with plated layer material, but connection failure may occur when the plated layer is thin
Solution Approach 1:
The patent applies preliminary action by forming a flat portion on the end portion of the lead-out portion before the plating process. This flat portion prevents groove formation during insulating coating removal by providing a controlled, flat surface for laser irradiation. The flat portion ensures that the insulating coating is removed uniformly without creating depressions or grooves that could trap plated layer material. This preliminary preparation eliminates the risk of connection failure due to groove-related plating defects, ensuring reliable electrical connection even with thin plated layers.
4Manufacturing precision
If stricter conditions are imposed on insulating coating removal to avoid residue and groove formation, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by mechanically forming a flat portion on the end portion of the lead-out portion before laser insulating coating removal. This preliminary mechanical preparation creates a controlled, flat surface that significantly relaxes the requirements for subsequent laser processing. Instead of requiring extremely precise laser parameters to avoid residue and groove formation, the flat portion provides a forgiving base that allows for wider process windows. This preliminary preparation enables less stringent process control while maintaining high manufacturing precision, thereby improving productivity without sacrificing quality.
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 suppresses connection failures, reduces plating time, minimizes damage to external resin films, and widens the acceptable conditions for insulating coating removal, enhancing productivity and adhesion of the plated layer.
Implementation Method 1
a body made of a magnetic portion including a magnetic powder and a resin, and containing the coil... the magnetic portion... improve adhesion and growth of the plated layer
Data Source
AI summary
The inductor includes a coil including a winding portion formed by winding a conductor wire having an insulating coating and lead-out portions extended from the winding portion, and a body made of a magnetic portion including magnetic powder and resin, and containing the coil, and outer electrodes on a body surface. The body includes a mounting surface, an upper surface opposite the mounting surface, a pair of opposing end surfaces adjacent to the mounting and upper surfaces, and a pair of opposing side surfaces adjacent to the mounting surface, the upper surface, and the end surfaces. End portions of the lead-out portions respectively have a flat portion exposed from the body surface, a covered portion adjacent to the flat portion at at least one of the end portions covered with the magnetic portion, and the flat portion is electrically connected to the outer electrode.