Common Mode Choke Coil Mg Segregation Glass Insulator
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Solution Overview
Problem
The existing laminated common mode choke coils face reliability issues due to fine pores in the glass layer, which compromise insulation properties as moisture penetrates through these pores, especially as electronic components become smaller and thinner.
Innovation Solution
Incorporating Mg segregation in the glass layer with a specific area ratio and size range, which reduces bubbles and enhances insulation properties by delaying densification, thereby improving moisture resistance and allowing for thickness reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass material is used as the insulator layer between two conductors, then insulation property is improved, but fine pores remain in the glass layer after sintering which reduces insulation reliability
Solution Approach 1:
The patent changes the chemical composition parameters of the glass material by adding specific amounts of MgO (0.5-5.0 wt%), SiO2 (60-80 wt%), B2O3 (10-30 wt%), and other oxides within defined ranges. This parameter optimization controls the sintering behavior to reduce pore formation while maintaining insulation properties and achieving simultaneous sintering with ferrite at 900-1100°C.
Solution Approach 2:
The patent creates a composite glass material system combining multiple oxide components (MgO, SiO2, B2O3, Al2O3, CaO, SrO, BaO, ZnO, PbO) to achieve synergistic effects. This composite composition enables simultaneous sintering with ferrite while controlling densification to minimize pore formation, and the specific MgO content provides moisture resistance without excessive bubble formation.
2Length of stationary object
If the glass layer is made thinner to reduce component thickness, then miniaturization is achieved, but insulation reliability may be compromised
Solution Approach 1:
The patent optimizes the glass layer thickness parameter to 5-20 μm while simultaneously optimizing the chemical composition (MgO: 0.5-5.0 wt%, SiO2: 60-80 wt%, B2O3: 10-30 wt%). This combined parameter optimization ensures that even at reduced thickness, the glass layer maintains sufficient insulation reliability by controlling pore formation through compositional design.
3Ease of manufacture
If sintering temperature is controlled for simultaneous sintering with ferrite, then manufacturing process is simplified, but fine pores remain due to densification
Solution Approach 1:
The patent identifies and optimizes multiple parameters including sintering temperature (900-1100°C), holding time (1-6 hours), and chemical composition (MgO: 0.5-5.0 wt%, SiO2: 60-80 wt%, B2O3: 10-30 wt%). This multi-parameter optimization enables simultaneous sintering with ferrite while controlling the densification process to minimize pore formation, achieving both manufacturing simplicity and high precision.
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
The Mg segregation in the glass layer effectively reduces bubble formation, enhancing insulation and moisture resistance, allowing for a thinner and more reliable common mode choke coil design.
Implementation Method 1
presence of Mg segregation of specific pattern in the glass layer reduces fine pores (bubbles) in the glass layer
Implementation Method 2
densification that results from sintering causes fine pores to remain in the glass layer
Implementation Method 3
reducing the bubbles in the glass layer lessens the permeation of water into the base body, thereby improving moisture resistance
Implementation Method 4
it is important to control the sintering temperature so that it can be sintered simultaneously with ferrite material
Data Source
AI summary
A common mode choke coil exhibiting greater reliability against moisture load includes a nonmagnetic layer made of glass, magnetic layers placed in a manner sandwiching the nonmagnetic layer, and two or more coil conductors embedded in a base material constituted by the nonmagnetic layer and magnetic layers, wherein Mg segregation is present in the nonmagnetic layer and the Mg segregation accounts for 0.5 to 16 percent of the total area as observed on an electron micrograph of a section of the nonmagnetic layer, while the size of Mg segregation is preferably 0.2 to 10 μm.