Recessed Magnetic Sheet Structure for Coil Bonding Reliability
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Solution Overview
Problem
The existing coil components experience interfacial peeling between the magnetic element body and the magnetic sheet, which can lead to increased leakage flux and noise, due to insufficient bonding.
Innovation Solution
A coil component design that includes a magnetic sheet with recesses on its surface, embedded within a metal powder and resin element body, which increases the bonding area and suppresses interfacial peeling by maximizing contact between the magnetic sheet and the element body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a magnetic sheet is provided inside a magnetic element body to reduce leakage flux, then noise is reduced, but interfacial peeling between the element body and magnetic sheet occurs due to insufficient bonding
Solution Approach 1:
The magnetic sheet is provided with recesses (curved/indented surfaces) instead of a flat surface, increasing the bonding area between the magnetic sheet and element body. This curvature-based modification allows better mechanical interlocking and suppresses interfacial peeling while maintaining the noise reduction function.
2Reliability
If the bonding area between magnetic sheet and element body is increased to suppress interfacial peeling, then reliability is improved, but the structural complexity of the magnetic sheet increases
Solution Approach 1:
The recesses in the magnetic sheet create a curved surface profile that increases bonding area without requiring multiple separate components or complex assembly structures. The curvature modification is achieved directly on the magnetic sheet surface, maintaining structural simplicity while improving reliability.
Data Source
AI summary
In a coil component, a recess provided on a surface of a magnetic sheet contributes to an enlargement of a bonding area between an element body and a magnetic sheet, and thus the interfacial peeling between the element body and the magnetic sheet is suppressed. In particular, since the magnetic sheet covers the entire region of the element body when viewed from the direction of the coil axis, the bonding area may be maximized and interfacial peeling may be further suppressed.