Planar Inductor Electrode Structure to Reduce Internal Stress
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Solution Overview
Problem
Conventional inductor components are prone to cracking or chipping due to high internal stress caused by the difference in expansion coefficient and elastic modulus between the external electrode and the element body, especially when thermal or mechanical stress is applied during manufacturing or mounting.
Innovation Solution
The inductor component design features a first external electrode with an uneven end edge extending orthogonally, reducing the amount embedded in the element body, and includes a second external electrode exposed from both the end and bottom surfaces, which reduces internal stress and prevents cracking or chipping by distributing stress more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the external electrode is embedded deeply in the element body to improve electrical connection, then the electrical connectivity is improved, but the internal stress increases due to difference in expansion coefficient and elastic modulus
Solution Approach 1:
The external electrode is designed with different embedded depths at different locations: the first external electrode has a first embedded depth in the first direction, while the second external electrode has a second embedded depth in the second direction. This local differentiation allows optimization of electrical connectivity in specific areas while reducing internal stress in other areas, resolving the contradiction between connectivity and stress.
Solution Approach 2:
The patent transitions from a single-dimensional embedding approach to a multi-dimensional approach by embedding external electrodes in different directions (first direction and second direction) with different embedded depths. This dimensional diversification allows the system to achieve both good electrical connectivity and reduced internal stress simultaneously.
2Strength
If the external electrode is embedded deeply in the element body to ensure mechanical strength, then the mechanical connection is improved, but cracking or chipping occurs under thermal or mechanical stress
Solution Approach 1:
Different external electrodes are embedded to different depths in different directions, creating local variations in mechanical strength distribution. This allows the structure to have sufficient mechanical connection where needed while avoiding stress concentration that leads to cracking in other areas.
Solution Approach 2:
The patent changes the embedding depth parameter of external electrodes based on their orientation and location. By adjusting this parameter, the system optimizes the balance between mechanical connection strength and resistance to thermal and mechanical stress, preventing cracking and chipping.
3Ease of manufacture
If the external electrode has a straight end edge to simplify manufacturing, then the manufacturing process is simplified, but the embedded amount is large causing high internal stress
Solution Approach 1:
The end edges of external electrodes are designed with different shapes in different directions: the first external electrode has a first end edge shape in the first direction, while the second external electrode has a second end edge shape in the second direction. This local differentiation reduces the embedded amount in specific areas, thereby reducing internal stress while maintaining manufacturing feasibility.
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 effectively suppresses cracking and chipping of the element body by minimizing internal stress, improving the fixing force and reducing parasitic capacitance, thereby enhancing the reliability and performance of the inductor component.
Implementation Method 1
internal stress of the element body generated due to difference in expansion coefficient and elastic modulus between the external electrode and the element body
Implementation Method 2
internal stress of the element body generated due to difference in expansion coefficient and elastic modulus between the external electrode and the element body
Data Source
AI summary
An inductor component comprising an element body including a first end surface and a second end surface opposite to each other, and a bottom surface connected between the first end surface and the second end surface; a coil disposed in the element body and including a coil conductor layer wound in a planar shape on a vertical plane for the first end surface, the second end surface, and the bottom surface; and a first external electrode and a second external electrode embedded in the element body so as to be exposed from at least the bottom surface and electrically connected to the coil. The first external electrode has an end edge extending in a direction orthogonal to the vertical plane, and the end edge is formed into an uneven shape.