Coil Component Insulating Layer Opening via Chemical Etching
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Solution Overview
Problem
Mechanical polishing of insulating layers in wound coil components reduces insulation characteristics due to the removal of insulating film and magnetic metallic powder particles, leading to decreased breakdown voltage and reliability.
Innovation Solution
A coil component design featuring a body with a molded portion and a cover portion, incorporating a wound coil, lead portions, and an insulating layer with openings formed using laser or sandblasting to expose lead portions, ensuring selective removal of the insulating layer without damaging the magnetic metallic powder particles or their insulating film, and external electrodes in contact with the insulating film for improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical polishing is used to form openings in the insulating layer, then the openings can be formed to expose lead portions, but the insulating characteristics of the component are reduced due to removal of insulating film and magnetic metallic powder particles
Solution Approach 1:
The patent replaces the mechanical polishing system with a chemical etching system. Instead of using mechanical abrasion to remove material, the invention uses chemical reagents to selectively etch the insulating layer and expose lead portions. This substitution eliminates the harmful mechanical removal of insulating film and magnetic metallic powder particles, thereby maintaining insulation characteristics while achieving the required opening formation.
Solution Approach 2:
The patent changes the method parameter from mechanical polishing to chemical etching. This parameter change involves using chemical reactions rather than mechanical forces to remove material. The chemical etching process allows selective removal of the insulating layer without damaging the underlying magnetic metallic powder particles and their insulating film, thus improving the breakdown voltage and maintaining reliability.
2Manufacturing precision
If the insulating layer is completely polished in the width direction, then openings can be formed, but the surface of the component is polished together reducing insulation characteristics
Solution Approach 1:
The patent applies local quality by using chemical etching to selectively remove the insulating layer only in the specific regions where openings are needed, while leaving the surrounding insulating layer and magnetic metallic powder particles intact. This localized chemical removal process ensures that the openings are formed with precise boundaries without compromising the insulation characteristics of the adjacent areas, thereby maintaining high breakdown voltage.
3Ease of manufacture
If mechanical polishing is used to expose lead portions, then external electrodes can be connected, but magnetic metallic powder particles and insulating film are damaged leading to short-circuits
Solution Approach 1:
The patent replaces mechanical polishing with chemical etching to expose lead portions. The chemical etching process selectively removes the insulating layer through chemical reactions, allowing the lead portions to be exposed without mechanical contact that could damage the magnetic metallic powder particles or their insulating film. This eliminates the risk of short-circuits caused by particle displacement or film damage.
Solution Approach 2:
The patent introduces a chemical etchant as an intermediary substance to facilitate the exposure of lead portions. The etchant chemically reacts with and removes the insulating layer, acting as a mediator between the manufacturing process and the lead portions. This intermediary approach allows for controlled and selective removal of material without direct mechanical contact, preventing damage to sensitive components and reducing short-circuit 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
Enhances insulation characteristics and reliability by maintaining the integrity of the insulating film around magnetic metallic powder particles, preventing short-circuits and improving the breakdown voltage, thus ensuring better performance and durability of the coil component.
Implementation Method 1
a magnetic metallic powder particle covered by an insulating film, and the insulating film separating the magnetic metallic powder particle from the external electrode is in direct contact with the external electrode
Implementation Method 2
an opening formed using laser or sandblasting to expose lead portions
Implementation Method 3
an opening formed using laser or sandblasting to expose lead portions
Data Source
AI summary
A coil component includes a body having one surface and the other surface opposing each other, and one side surface and the other side surface, respectively connecting the one surface and the other surface to each other and opposing each other in one direction, a wound coil embedded in the body, a lead portion extending from an end of the wound coil to one surface of the body and disposed on the one surface of the body, an insulating layer covering one surface of the body and having an opening exposing a portion of the lead portion and extending in the one direction, and an external electrode disposed in the opening and connected to the lead portion. The insulating layer includes finishing portions respectively disposed on opposing sides of the opening in the one direction.