Thin-Film Coil Structure for Single-Direction Component Separation
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Solution Overview
Problem
The existing dicing process for thin-film coil components, which involves cutting in both length and width directions, often results in alignment discrepancies between the dicing lines and saw, leading to increased defects.
Innovation Solution
A coil component design that omits the dicing process in one direction by exposing magnetic metal powder particles with specific surface configurations and using an insulating substrate, allowing for separation of components without additional cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dicing is performed twice (in both length and width directions), then components can be separated into individual units, but alignment between dicing line and dicing saw becomes dislocated, increasing defects
Solution Approach 1:
The patent extracts the dicing process from one direction (either length or width) by designing the coil bar to have a separation structure that allows components to be separated without cutting in that direction. This reduces the number of dicing operations from two to one, eliminating alignment issues while maintaining component separability.
Solution Approach 2:
The coil bar is segmented into individual component regions with clear separation structures (such as grooves or gaps) that allow components to be divided into individual units through a single dicing process. The segmentation is designed so that components can be separated along one axis without requiring cutting in both directions.
2Ease of manufacture
If dicing is performed in both length and width directions, then individual components can be obtained, but production efficiency decreases due to multiple processing steps
Solution Approach 1:
The patent removes one dicing operation from the manufacturing process by designing the coil bar with inherent separation features in one direction. This extraction of the redundant dicing step reduces processing time and increases production efficiency while still enabling complete component separation.
Solution Approach 2:
The coil bar is preliminarily structured with separation grooves or gaps during the molding process, preparing the components for easy separation. This preliminary action eliminates the need for subsequent dicing in one direction, streamlining the manufacturing process and improving productivity.
3Reliability
If magnetic metal powder particles are exposed to all wall surfaces, then magnetic properties are enhanced, but surface flatness for lead-out pattern exposure is compromised
Solution Approach 1:
The patent applies local quality by exposing magnetic metal powder particles to only certain wall surfaces (either first or second wall surfaces, but not both) rather than all surfaces. This selective exposure maintains adequate magnetic properties while ensuring flat surfaces are available for lead-out pattern exposure, resolving the conflict between magnetic performance and manufacturing precision.
Data Source
AI summary
A coil component includes a body having a first surface and a second surface opposing each other and a plurality of wall surfaces connecting the first surface to the second surface, and including insulating resin and magnetic metal powder particles; an insulating substrate disposed in the body; a coil portion disposed on the insulating substrate and including a lead-out pattern exposed to a first wall surface of the plurality of wall surfaces of the body; and an external electrode disposed on the body and connected to the lead-out pattern. Some of the magnetic metal powder particles are exposed to each of the plurality of wall surfaces of the body. The magnetic metal powder particles exposed to the first wall surface of the body have a cut-out surface. The magnetic metal powder particles exposed to a second wall surface connected to the first wall surface of the plurality of wall surfaces of the body do not have a cut-out surface.