Multilayer Coil Extended-Conductor Structure for Sintering Bubble Control
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Solution Overview
Problem
Existing multilayer coil components experience wire breakage at the extended-conductor connection portion due to bubble formation during the sintering process, which concentrates at the bent transition areas, leading to connectivity issues.
Innovation Solution
The multilayer coil component design includes extended conductors with a controlled pore area ratio of 1.00% to 11.00% and a manufacturing method that uses specific conductor paste compositions and sintering processes to minimize bubble concentration, ensuring reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the extended electrode is exposed to the outside during sintering, then the sintering process can be completed, but bubbles concentrate in the bent portion causing wire breakage
Solution Approach 1:
The patent applies preliminary action by covering the extended electrode with the outer electrode before the sintering process begins. This preventive measure ensures that bubbles generated during sintering are contained and do not concentrate in the bent portion, thereby preventing wire breakage while still allowing the sintering process to complete successfully.
2Reliability
If the transition portion is bent to connect coil and extended electrode, then electrical connection is achieved, but bubble concentration occurs at the bent portion
Solution Approach 1:
The patent converts the harmful effect of bubble generation during sintering into a beneficial outcome by using the outer electrode as a barrier. The outer electrode, which must cover the extended electrode for proper electrical connection, simultaneously prevents bubbles from concentrating in the bent transition portion, thus transforming the potential harm into a protective function.
3Reliability
If the extended electrode area is large, then connectivity is improved, but bubble attraction to the exposed portion increases
Solution Approach 1:
The patent introduces the outer electrode as an intermediary element between the extended electrode and the external environment. This intermediary structure allows the extended electrode to maintain its large area for good connectivity while preventing direct interaction with bubbles during sintering, as the outer electrode acts as a protective barrier.
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 design reduces the risk of wire breakage and maintains reliable electrical continuity by distributing pores uniformly, preventing concentration at the transition points and enhancing the durability of the extended-conductor connections.
Implementation Method 1
when the conductor paste is sintered to form the coil conductor and the extended electrode
Data Source
AI summary
A multilayer coil component includes a multilayer body formed by laminating multiple insulating layers and having an inner electrode and first and second outer electrodes, each of which is electrically connected to the inner electrode. The inner electrode includes a coil formed by laminating multiple coil conductors together with the insulating layers, the coil conductors being electrically connected together, a first extended conductor connecting between the coil and the first outer electrode, and a second extended conductor connecting between the coil and the second outer electrode. The first and second extended conductors extend in a lamination direction in which the insulating layers are laminated. A coil conductor connected directly to the first extended conductor is a first coil conductor, and a coil conductor connected directly to the second extended conductor is a second coil conductor.