Laminated Coil Structure to Minimize End-Surface Coil Marks
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Solution Overview
Problem
Conventional methods of manufacturing laminated coil components result in defects during outer electrode formation due to coil marks, particularly when the size of the components increases or the number of laminated layers increases, leading to bubbles being trapped in depressions on the end surfaces.
Innovation Solution
Incorporating plate-shaped members with insulation layers to reduce the depth of coil marks, ensuring they are smaller and less likely to cause structural defects in the outer electrodes, by adjusting the dimensions and locations of these members relative to the coil conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of laminated coil components is increased or the number of laminated layers is increased to improve performance, then the performance is improved, but the depth of coil marks increases causing defects in outer electrode formation
Solution Approach 1:
A plate-shaped member is introduced as an intermediary element between the coil conductors and the end surface. This plate-shaped member acts as a mediator that prevents the coil conductors from directly causing depressions on the end surface, thereby eliminating the harmful effect of coil marks while allowing the component size and layer count to increase for improved performance
2Ease of manufacture
If conventional manufacturing methods are used without plate-shaped members, then the manufacturing process is simple, but coil marks cause bubbles to be trapped in depressions leading to defects in outer electrode formation
Solution Approach 1:
The plate-shaped member serves as a simple intermediary component that is laminated together with the insulation layers. Its addition does not significantly complicate the manufacturing process while effectively preventing the formation of deep coil marks that would trap bubbles and cause defects in outer electrode formation
Data Source
AI summary
A laminated coil component includes a multilayer body including laminated insulation layers and a coil inside; and first and second outer electrodes electrically connected to the coil. The coil is composed of coil conductors laminated together with the insulation layers and electrically connected to one another. The multilayer body has first and second end surfaces opposed to each other in a longitudinal direction, first and second main surfaces opposed to each other in a height direction orthogonal to the longitudinal direction, and first and second side surfaces opposed to each other in a width direction orthogonal to the longitudinal direction and the height direction. A coil axis of the coil is parallel to the first main surface. The multilayer body further includes a plate-shaped member laminated together with the insulation layers.