Air-Core Coil Packaging with Exposed Ground Electrode
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Solution Overview
Problem
The manufacturing of sealed coil-type magnetic components under high pressure often results in deformation or breakage of air-core coils, leading to reduced yield, and the low magnetic permeability of thermoplastic resin in power supply modules causes electromagnetic interference.
Innovation Solution
A method involving a T-shaped core and air-core coil embedded in a mixture of metal composite magnetic material and resin, with a ground connection electrode exposed outside the package to prevent static electricity and reduce electromagnetic interference, using a metal mold and controlled pressure to minimize component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied to seal the air-core coil with magnetic powder and resin mixture, then the coil is sealed effectively, but the air-core coil may be deformed or broken
Solution Approach 1:
The patent applies preliminary action by pre-forming the magnetic powder and resin mixture into a mold before placing the air-core coil, then filling the remaining space with additional mixture. This preliminary structuring allows the coil to be sealed effectively without requiring excessive pressing force that would deform or break the coil, thus resolving the contradiction between sealing effectiveness and coil integrity.
2Ease of manufacture
If thermoplastic resin is injected to assemble electronic components, then the components are secured, but electromagnetic interference occurs due to low magnetic permeability
Solution Approach 1:
The patent uses a composite material consisting of magnetic powder particles dispersed in a resin matrix. This composite structure combines the sealing and mechanical support properties of the resin with the electromagnetic shielding properties of the magnetic powder, effectively reducing electromagnetic interference while maintaining ease of manufacture through injection molding. The magnetic powder particles create magnetic pathways that contain electromagnetic fields within the package.
3Object-generated harmful factors
If the coil is fully enclosed in the magnetic material mixture, then electromagnetic interference is reduced, but static electricity causes insulation breakdown
Solution Approach 1:
The patent applies local quality by creating different properties in different regions of the package. The magnetic powder and resin mixture provides electromagnetic shielding in the bulk, while deliberately leaving the ground connection electrode exposed at the surface. This exposed electrode provides a local conductive path to ground that dissipates static electricity without compromising the overall electromagnetic shielding provided by the enclosed magnetic material.
4Object-affected harmful factors
If ground connection electrode is exposed outside the package, then static electricity resistance is improved, but the package structure becomes more complex
Solution Approach 1:
The patent merges the ground connection electrode with the package structure by forming the electrode as an integral part of the molded package. The electrode is incorporated into the mold cavity and remains exposed at the surface after molding, eliminating the need for separate electrode components or additional assembly steps. This integration provides static electricity dissipation while minimizing structural complexity.
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 enhances the manufacturing yield of electronic components with superior static electricity resistance and reduces electromagnetic interference, while maintaining a low pressure to prevent coil deformation and breakage, thus lowering production costs.
Implementation Method 1
a mixture of a metal composite magnetic material and a resin that is formed on the circuit board and that covers the coil component and the ground connection electrode as a package
Implementation Method 2
heating the mixture at a first temperature, hardening the mixture
Data Source
AI summary
An electronic component includes a circuit board that includes a ground terminal connected to a ground potential, a coil component that is assembled on the circuit board, the coil component includes a T-shaped core and an air-core coil, a ground connection electrode that is assembled on the circuit board next to the coil component and that is connected to the ground terminal, and a mixture of a metal composite magnetic material and a resin that is formed on the circuit board and that covers the coil component and the ground connection electrode as a package. A part of the ground connection electrode is exposed outside the mixture.