Thin Coil Inductor Electrode Layout for Reliable Lead Contact
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Solution Overview
Problem
Inductors face challenges in reducing thickness while maintaining high performance and reliability due to contact defects between coils and external electrodes, which affect inductance and efficiency.
Innovation Solution
A coil electronic component with a body made of magnetic metal material, featuring plating electrodes formed on the surface that extend from the body to the lead parts, and an insulating layer on the outer surfaces except where electrodes are formed, reducing the risk of contact defects and allowing for thinner, more efficient external electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of the inductor body is reduced to meet device thinness requirements, then the overall size and thickness are improved, but the volume of the body decreases leading to reduced inductance and increased risk of contact defects between coil and external electrodes
Solution Approach 1:
The patent extends the external electrodes not only on the top and bottom surfaces but also on the side surfaces of the inductor body. This multi-dimensional electrode arrangement ensures sufficient contact area between the external electrodes and the coil leads even when the body thickness is reduced, thereby maintaining contact reliability while achieving thinness requirements.
2Length of moving object
If the thickness of the inductor body is reduced, then the overall size is improved, but the volume of the body decreases leading to reduced inductance
Solution Approach 1:
By extending electrodes onto side surfaces, the patent effectively utilizes three-dimensional space for electrode placement. This allows the main body to be thinned while the electrode contact paths are maintained through lateral extensions, preserving functional volume without increasing overall thickness.
3Length of moving object
If external electrodes are made thinner to reduce overall thickness, then the inductor thickness is improved, but the contact area between external electrodes and coil leads decreases increasing contact defect risk
Solution Approach 1:
The patent compensates for reduced electrode thickness by extending electrodes in lateral dimensions along the side surfaces. This multi-directional extension ensures sufficient contact area and overlap with coil leads, maintaining manufacturing precision and contact reliability even with thinner electrode structures.
Solution Approach 2:
The extended side surface electrodes create overlapping contact zones that nest between the coil windings and the body surface. This nested arrangement ensures multiple contact points and redundant contact paths, improving contact precision and reducing defect risk.
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 design prevents contact defects, increases the volume of the body, and enhances inductance, DC-bias characteristics, and efficiency by reducing material costs and the risk of short circuits.
Implementation Method 1
A first plating electrode is formed on the first surface of the body and a further surface of the body connected to and extending from the first surface of the body, and connected to the first lead part. A second plating electrode is formed on the second surface of the body
Data Source
AI summary
A coil electrode component includes a body including magnetic metal material, a coil disposed in the body and having first and second lead parts respectively outwardly exposed through first and second surfaces of the body. A first plating electrode is formed on the first surface of the body and a further surface of the body connected to and extended from the first surface of the body, and connected to the first lead part. A second plating electrode is formed on the second surface of the body and a further surface of the body connected to and extended from the second surface of the body, and connected to the second lead part.