Coil Component Magnetic Layer Plating for Inductance

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Solution Overview

Problem

Miniaturization of chip electronic components, such as thin layer inductors, has led to decreased inductance and quality factor due to reduced volume and number of coil turns, making it difficult to achieve target inductance and quality factor while maintaining high permeability.

Innovation Solution

A coil electronic component with a magnetic body and a high permeability magnetic layer formed on its surfaces, using a plating process, which includes a metallic layer of iron, silicon, or other metals, and an insulating cover layer to prevent short-circuit defects and flux loss, while the coil part is embedded within the magnetic body and lead parts extend to the surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the size of chip electronic components is miniaturized, then the volume and number of coil turns are reduced, but the inductance and quality factor decrease

Engineering Contradiction:

Improvevolume of chip componentVSAvoidinductance and quality factor

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies local quality by forming a magnetic layer with high permeability specifically on the surface of the magnetic body, rather than requiring the entire component to be large. This localized enhancement of magnetic properties at the surface compensates for the reduced volume, maintaining inductance and quality factor despite miniaturization.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining the magnetic body (made of magnetic powder and resin) with a separate magnetic layer formed by plating. This composite structure allows the core to be small while the surface layer provides enhanced magnetic permeability, resolving the contradiction between miniaturization and maintaining electromagnetic performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the permeability of magnetic material is increased to maintain inductance, then the manufacturing complexity increases

Engineering Contradiction:

ImproveinductanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the magnetic structure into two parts: the magnetic body (core) and the magnetic layer formed on its surface. This segmentation allows the bulk material to remain simple (magnetic powder + resin) while the surface layer provides the necessary high permeability, simplifying manufacturing compared to requiring the entire component to be made of high-permeability material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the permeability parameter locally by adding a magnetic layer on the surface, rather than changing the permeability of the entire magnetic body. This parameter change approach maintains inductance while keeping the manufacturing process simple, as the magnetic layer can be formed by standard plating processes.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a magnetic layer is formed on the surface of the magnetic body, then the permeability and inductance increase, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvepermeability and inductanceVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a plating seed layer as an intermediary between the magnetic body and the magnetic layer. This seed layer facilitates the plating process by providing a conductive base, making the formation of the magnetic layer easier and more controllable, thus reducing manufacturing complexity while achieving the desired permeability enhancement.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Volume of moving object

If the number of coil turns is reduced due to miniaturization, then the component size decreases, but the inductance decreases

Engineering Contradiction:

Improvecomponent sizeVSAvoidinductance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent compensates for the reduced number of coil turns by enhancing the magnetic properties locally through the magnetic layer on the surface. This localized improvement in permeability increases the inductance despite fewer turns, allowing miniaturization without sacrificing electromagnetic performance.

Inventive Principle:

Principle #3Local quality

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 increases the permeability and inductance of the coil electronic component without increasing the magnetic material's permeability, enhancing the quality factor and preventing magnetic flux loss, thus addressing the limitations of miniaturization.

Implementation Method 1

The magnetic layer may be formed by a plating process

Methodology Applied

Scientific EffectPlating process: Electroplating

Implementation Method 2

a magnetic body comprising a magnetic material; a coil part embedded in the magnetic body

Methodology Applied

Scientific EffectMagnetic flux: Magnetic Field

Data Source

PatentUS10102964B2Coil electronic component and manufacturing method thereof

Publication Date: 2018.10.16 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A coil electronic component includes: a magnetic body comprising a magnetic material; a coil part embedded inside the magnetic body; and a magnetic layer disposed on a surface of the magnetic body.