Coil Component Insulating Layer Slits Prevent Plating Bleeding
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Solution Overview
Problem
The challenge in manufacturing thin film power inductors is plating bleeding on the surface of magnetic metal powder-resin composite bodies during the formation of external electrodes, which affects the component's reliability and surface area of the magnetic material.
Innovation Solution
A coil component design featuring a support substrate with a coil portion embedded within a body, an insulating layer, and an oxide insulating layer with slits on the surface to prevent plating bleeding and reduce the magnetic material's surface area, thereby maintaining component characteristics and preventing deformation due to thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is formed on the surface of the body to prevent plating bleeding, then reliability is improved, but the surface area of the magnetic material decreases
Solution Approach 1:
The insulating layer is divided into multiple regions: a first insulating layer covering the entire body surface, and a second insulating layer with slits formed only in specific regions where plating bleeding occurs. This segmentation allows the insulating layer to provide comprehensive coverage while maintaining magnetic surface area in non-problem areas.
Solution Approach 2:
The insulating layer has different properties in different regions: in regions where plating bleeding occurs, the insulating layer is present to prevent bleeding, while in other regions, the magnetic material surface is exposed to maintain surface area. This local differentiation optimizes both reliability and magnetic performance.
2Reliability
If the surface area of magnetic material is reduced to prevent plating bleeding, then reliability is improved, but inductance decreases
Solution Approach 1:
The insulating layer is segmented to cover only specific regions where plating bleeding occurs, rather than the entire surface. This allows the magnetic material surface area to be preserved in regions not susceptible to plating bleeding, thereby maintaining inductance while still preventing reliability issues.
Solution Approach 2:
The insulating layer provides localized protection only where needed, allowing the magnetic material to maintain its full surface area and inductance characteristics in regions where plating bleeding is not a concern, thus preserving power performance.
3Reliability
If a complete insulating layer is formed on all surfaces, then plating bleeding is prevented, but manufacturing complexity increases
Solution Approach 1:
The insulating layer structure is segmented into a first insulating layer covering the entire body and a second insulating layer with slits in specific regions. This segmentation simplifies the overall structure compared to a complete continuous insulating layer, as it allows selective coverage only where plating bleeding occurs.
Solution Approach 2:
The insulating layer is applied with local quality differentiation, providing insulation only in regions where plating bleeding is a problem. This reduces manufacturing complexity by avoiding the need for a complete continuous insulating layer across all surfaces, thereby simplifying the manufacturing process while maintaining reliability.
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 solution effectively prevents plating bleeding and reduces the surface area loss of the magnetic material, enhancing the reliability and inductance of the coil component while minimizing the decrease in magnetic surface area.
Implementation Method 1
an oxide insulating layer disposed on each of the one side surface and the other side surface of the body and each of the one end surface and the other end surface of the body
Data Source
AI summary
A coil component includes a support substrate and a coil portion disposed on the support substrate, a body, in which the support substrate and the coil portion are embedded, having one surface and the other surface, one side surface and the other side surface, and one end surface and the other end surface, a first lead-out portion and a second lead-out portion, respectively extending from the coil portion to be exposed from the one side surface and the other side surface, an insulating layer disposed on each of the one surface and the other surface, and an oxide insulating layer disposed on each of the one side surface and the other side surface and each of the one end surface and the other end surface. The insulating layer is provided with a plurality of slits spaced apart from each other to expose a surface of the body.