Laminated Coil Structure With Local Voids for Stress Relaxation
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Solution Overview
Problem
Existing laminated coil components do not exhibit sufficient stress relaxation when stress relaxation spaces are formed only on one surface or the other surface of the coil conductors, leading to insufficient strength of the multilayer body and decreased productivity due to additional processing steps.
Innovation Solution
A laminated coil component with a multilayer body where coil conductors are laminated with insulation layers and connected via via conductors, featuring voids on both main surfaces of the coil conductors to enhance stress relaxation while maintaining strength, and produced using a printed sheet lamination method to improve productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stress relaxation spaces are formed only on one surface or the other surface of the coil conductors, then the manufacturing process is simpler, but the stress relaxation effect is insufficient
Solution Approach 1:
The patent applies local quality by forming voids at specific locations on the coil conductors - specifically on the first main surface of all coil conductors and on the second main surface of alternate coil conductors (e.g., every other conductor). This selective, non-uniform distribution of voids provides adequate stress relaxation while avoiding the need to process all surfaces, thus balancing manufacturing simplicity with stress relaxation effectiveness.
2Reliability
If stress relaxation spaces are formed on both surfaces of the coil conductors, then the stress relaxation effect is improved, but the strength of the multilayer body becomes insufficient
Solution Approach 1:
The patent resolves this contradiction by applying local quality - voids are formed only on the first main surface of all coil conductors and only on the second main surface of alternate coil conductors, not on all surfaces. This selective approach provides sufficient stress relaxation while preserving structural integrity by maintaining contact between coil conductors and insulation layers at locations where voids are not formed.
3Reliability
If stress relaxation spaces are formed on both surfaces of the coil conductors, then the stress relaxation effect is improved, but productivity declines due to additional processing steps
Solution Approach 1:
The patent improves productivity while maintaining stress relaxation by applying local quality - voids are formed selectively on specific surfaces and specific conductors rather than on all surfaces of all conductors. This reduces the number of screening and firing operations needed, eliminating the requirement for separate ZrO2 paste application on both surfaces, thus improving manufacturing efficiency.
Data Source
AI summary
A laminated coil component includes a multilayer body in which a coil, which is obtained by electrically connecting a plurality of coil conductors with a via conductor interposed therebetween, is provided in an inside of an insulator portion which is obtained by laminating a plurality of insulation layers. Each of a first coil conductor and a second coil conductor that are adjacent to each other in a lamination direction and are electrically connected in series with a first via conductor interposed therebetween includes a first main surface that faces the opposite direction to the lamination direction and on which a void exists. The second coil conductor includes a second main surface that faces the lamination direction and on which another void exists, and the other void locally exists on a position opposed to the first via conductor.