Power Inductor Electrode Structure for Reliable Coil Contact
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Solution Overview
Problem
Existing metal-based power inductors face challenges in achieving reliable contact between internal coils and external electrodes, which is crucial for high reliability and miniaturization in electronic components.
Innovation Solution
The coil component features a support member with cut surfaces and a composite external electrode structure, including a conductive resin layer, to improve contact reliability and reduce overall thickness, enhancing magnetic permeability and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a metal-based power inductor is designed for miniaturization, then the size is reduced, but the contact reliability between internal coils and external electrodes deteriorates
Solution Approach 1:
The external electrode is segmented into multiple layers: a first external electrode layer in direct contact with the internal coil, and a second external electrode layer disposed on the first layer. This segmentation allows the first layer to provide reliable electrical contact while the second layer provides structural support and soldering surface, thereby maintaining contact reliability in miniaturized designs.
Solution Approach 2:
The first external electrode layer is formed as a composite structure including a conductive material and a resin. This composite material provides both excellent electrical conductivity for reliable signal transmission and adequate mechanical strength for structural integrity, ensuring contact reliability even when the overall component size is reduced.
2Ease of manufacture
If the support member surfaces are made parallel to major surfaces, then manufacturing is simpler, but magnetic permeability and adhesion are reduced
Solution Approach 1:
The support member features cut surfaces with specific orientations (non-parallel to major surfaces) at critical locations where external electrodes are disposed. This local modification of surface geometry enhances magnetic permeability and adhesion in the electrode contact regions while maintaining parallel surfaces in other areas for ease of manufacturing. The selective application of different surface qualities resolves the contradiction between manufacturing simplicity and performance.
Data Source
AI summary
A coil component includes a support member, an internal coil supported by the support member and including a plurality of coil patterns, and external electrodes connected to the internal coil and including a first layer in contact with the internal coil and a second layer disposed on the first layer. The second layer is a composite layer including a conductive material and a resin. The support member includes first and second surfaces facing the external electrodes, respectively, and one or more of at least a portion of the first surface and at least a portion of the second surface are configured as cut surfaces.