Multilayer Inductor Electrode Structure to Prevent Peeling
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Solution Overview
Problem
Existing multilayer inductors face issues with peeling-off of the external electrode from the element body, which is not adequately addressed in prior art.
Innovation Solution
The multilayer inductor design includes a configuration where the external electrode has specific portions exposed at the main surface and within the element body, with outer edges coinciding with imaginary planes orthogonal to the main surface, enhancing the anchor effect and increasing contact area to prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the external electrode is disposed on the element body with conventional configuration, then the electrical connection is achieved, but the peeling-off of the external electrode from the element body occurs
Solution Approach 1:
The patent extends the external electrode configuration from a conventional two-dimensional surface mounting to a three-dimensional structure that includes depth into the element body. The electrode portions are disposed at different depths, with first electrode portions at a first depth and second electrode portions at a second depth greater than the first depth, creating a multi-layered anchoring system that prevents peeling-off by distributing bonding stress across multiple dimensions.
Solution Approach 2:
The patent implements a nested electrode structure where second electrode portions are positioned deeper within the element body than first electrode portions, creating a hierarchical anchoring system. This nested configuration allows the electrode to be embedded progressively deeper into the element body, with each layer providing additional bonding strength and resistance to peeling forces.
2Reliability
If the electrode portions are disposed at different depths within the element body, then the peeling-off is prevented, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the external electrode into multiple discrete electrode portions (first electrode portions and second electrode portions) that are disposed at different depths within the element body. This segmentation allows each portion to be independently positioned and bonded, simplifying the manufacturing process by enabling step-by-step assembly while achieving the complex multi-depth configuration that prevents peeling-off.
Data Source
AI summary
The element body includes a main surface, and a side surface located on imaginary planes orthogonal to the main surface. The external electrode includes first, second and third electrode portions. The first electrode portion is exposed at the main surface. The second electrode portion is continuous with the first electrode portion and exposed at the main surface. The second electrode portion is located to extend from the first electrode portion to the imaginary planes when viewed in a direction orthogonal to the main surface. The third electrode portion is continuous with the first electrode portion and is separated from the second electrode portion in the direction orthogonal to the main surface. The third electrode portion includes outer edges coinciding with the imaginary planes when viewed in the direction orthogonal to the main surface. The element body includes a part between the second electrode portion and the third electrode portion.