Coil Component Insulating Resin Body Formation
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Solution Overview
Problem
The challenge in miniaturized electronic devices is the efficient insulation of power inductors, which requires both L and bottom electrodes, leading to increased complexity and costs in the chip manufacturing process, with existing methods like screen-printing being inefficient and time-consuming.
Innovation Solution
A coil component design featuring a body with a hexahedral shape, incorporating a magnetic material and insulating resin, with an insulating member comprising multiple layers on its side surfaces to reduce the need for side insulation and improve plating spread, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screen-printing method is used for side insulation, then insulation is achieved, but manufacturing time and cost increase
Solution Approach 1:
The insulating resin is mixed with the magnetic material before sintering to form the body, performing the insulation action in advance during body formation rather than as a separate post-processing step. This eliminates the need for subsequent screen-printing of insulating paste and reduces manufacturing time while ensuring insulation quality.
2Reliability
If screen-printing method is used for side insulation, then insulation is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The insulation function is merged with the body formation process by incorporating insulating resin into the magnetic material mixture before sintering. This combines two separate processes (body formation and insulation application) into one, reducing manufacturing process complexity and cost while maintaining insulation quality.
Solution Approach 2:
The magnetic material serves multiple functions: it provides the magnetic properties necessary for inductor operation and simultaneously acts as an insulating matrix when mixed with insulating resin. This multi-functionality eliminates the need for separate insulating materials and processes, simplifying the overall manufacturing process.
3Reliability
If traditional insulation process is used, then current flow control is achieved, but plating spread is reduced
Solution Approach 1:
The insulating resin is distributed locally within the magnetic material matrix at the side surfaces of the body, providing insulation exactly where needed without creating a thick external insulating layer. This localized insulation approach maintains good electrical isolation while preserving plating spread characteristics on the external surfaces.
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 design reduces the incidence of defective products, decreases manufacturing costs and time by eliminating the need for a side insulation process, and enhances plating spread, making it suitable for mounting on microcircuit substrates.
Implementation Method 1
a body (magnetic metal), and an electrode portion (Cu, Ni, and Sn), which are all conductors, and in order to allow current to selectively flow, a process of insulating unnecessary parts is essentially entailed
Data Source
AI summary
A coil component includes a body having first to fourth side surfaces, a coil disposed in the body, and an insulating member disposed on at least one of the first to fourth side surfaces of the body and including first to third insulating layers. The insulating member may include first and second insulating members respectively disposed on the third and fourth side surfaces.