Planar Coil Component Lid-Post Structure for Magnetic Filler Adhesion
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Solution Overview
Problem
Existing coil components face issues with magnetic fillers detaching due to internal stress and external forces, particularly at the interface between the magnetic layer and the electrode lead-out portion, leading to poor adhesion and reduced saturation magnetic flux density.
Innovation Solution
A coil component design featuring a conductor post with a post portion and a lid portion, where the lid portion extends from the conductor post's end on the outer surface, covering the surrounding area and increasing the contact area with the external terminal, thereby enhancing adhesion and preventing magnetic filler detachment, while maintaining the volume and saturation magnetic flux density of the magnetic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional conductor post structure is used, then the manufacturing process is simple, but the magnetic filler falls off at the interface between the magnetic layer and electrode lead-out portion
Solution Approach 1:
The conductor post is segmented into a post portion and a lid portion, where the lid portion specifically addresses the adhesion problem at the interface between the magnetic layer and electrode lead-out portion. This segmentation adds minimal manufacturing complexity while effectively preventing magnetic filler detachment.
Solution Approach 2:
The lid portion is positioned locally at the end of the conductor post where it interfaces with the magnetic filler in the covering portion. This localized structure provides enhanced coverage and adhesion precisely where needed, without complicating the overall conductor post structure or manufacturing process.
2Reliability
If the contact area between the conductor post and external terminal is increased, then the electrical connection reliability is improved, but the volume of the magnetic layer is increased
Solution Approach 1:
The lid portion extends from the end of the post portion in a direction substantially perpendicular to the axial direction of the planar coil, utilizing a horizontal dimension rather than increasing vertical height. This dimensional change allows the lid portion to provide extensive coverage for electrical connection and magnetic filler support without significantly increasing the overall volume of the magnetic layer.
Solution Approach 2:
The lid portion functions as a thin, extended structure that provides large surface area for electrical connection and magnetic filler coverage without adding substantial volume. This thin-film-like structure achieves improved electrical connection reliability while maintaining compact magnetic layer dimensions.
Data Source
AI summary
There is provided a coil component including a coil portion that has at least one layer of planar coil including a coil-wound portion and an insulative layer which covers the periphery of the coil-wound portion, a covering portion that covers the coil portion and is constituted of a mixture including magnetic fillers and resin, and a conductor post that is penetratingly provided inside the covering portion and extends from the coil-wound portion to an upper surface of the covering portion along an axial direction of the planar coil. The conductor post has a post portion which extends from the coil-wound portion in the axial direction of the planar coil, and a lid portion which is exposed from the covering portion and extends from an end portion of the post portion on the upper surface side along a surface direction of the upper surface.