Plated External Electrodes for Magnetic Components With Low Contact Resistance
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Solution Overview
Problem
Existing inductor manufacturing methods face issues with contact defects between the internal coil part and external electrodes, leading to increased contact resistance and manufacturing costs, while also limiting the volume of the magnetic body, which affects inductance and efficiency.
Innovation Solution
The electronic component features external electrodes formed directly on the magnetic body through plating, using magnetic metal powder, which eliminates the need for conductive resin paste, allowing for precise thickness control and reducing manufacturing costs, and includes multiple plating layers to enhance connectivity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductive resin paste is used to form external electrodes, then manufacturing process is simplified, but contact defects occur and contact resistance increases
Solution Approach 1:
The patent introduces a plating layer as an intermediary between the magnetic body and the external electrode. This plating layer serves as a mediator that ensures reliable electrical contact while maintaining manufacturing simplicity. The plating layer is formed by electroplating metal particles onto the magnetic body surface, creating a conductive interface that eliminates contact defects associated with direct conductive resin paste application.
Solution Approach 2:
The patent changes the physical and chemical parameters of the electrode formation process by transitioning from conductive resin paste to electroplating. This involves changing the deposition mechanism from screen printing to electrochemical deposition, which provides better control over layer thickness, composition, and electrical properties, thereby improving contact reliability.
2Reliability
If magnetic body volume is increased to improve inductance, then inductance and efficiency improve, but manufacturing complexity increases
Solution Approach 1:
The patent segments the electrode structure into multiple functional layers: a plating layer directly on the magnetic body, and an external electrode layer on top of the plating layer. This segmentation allows each layer to perform its specific function optimally - the plating layer ensures good electrical contact and low resistance, while the external electrode provides the necessary mechanical and electrical interface, thereby managing manufacturing complexity through functional decomposition.
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
This approach prevents contact defects, improves inductance and efficiency by increasing the magnetic body volume, and decreases manufacturing costs by avoiding the use of expensive conductive resin pastes.
Implementation Method 1
external electrodes disposed on an outer portion of the magnetic body, wherein the external electrodes include first plating layers formed to directly contact the magnetic body
Data Source
AI summary
An electronic component includes a magnetic body containing magnetic metal powder; and external electrodes disposed on an outer portion of the magnetic body. The external electrodes include first plating layers in direct contact with the magnetic body.