Coil Component Recessed Insulating Layer Anchor Effect
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Solution Overview
Problem
Conventional coil components experience peeling issues between the magnetic resin layer and the insulating resin layer due to differences in thermal expansion coefficients, leading to reliability and durability concerns during testing.
Innovation Solution
A coil component design featuring alternately laminated conductor layers and interlayer insulating layers with a recessed part in the side wall surface, where the sealing resin layer, specifically a magnetic resin layer with metal magnetic particles, is embedded in the recessed part to enhance adhesion through an anchor effect, while ensuring uniform plating and insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic resin layer is used to cover the coil part, then magnetic shielding and insulation properties are improved, but peeling occurs at the boundary due to thermal expansion coefficient differences
Solution Approach 1:
A recessed part is formed in the side wall surface of the interlayer insulating layer before applying the sealing resin layer. This preliminary structural preparation allows the sealing resin to mechanically interlock with the coil part, creating an anchor effect that prevents peeling during thermal expansion and contraction cycles.
Solution Approach 2:
The recessed part is strategically positioned at specific locations on the interlayer insulating layer where enhanced adhesion is needed. This localized structural modification allows the sealing resin to bite into the interlayer insulating layer only where necessary, improving bond strength without compromising the overall structure or requiring changes to the entire component.
2Reliability
If the sealing resin layer is made to bite into the interlayer insulating layer, then adhesion is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The recessed part formation process is merged with the existing manufacturing workflow by utilizing the auxiliary pattern structure that is already part of the coil component design. The auxiliary pattern serves dual purposes: enabling electrolytic plating and providing the recessed structure for enhanced adhesion, thereby reducing overall manufacturing complexity despite the added functional benefit.
3Manufacturing precision
If auxiliary patterns are added to enable electrolytic plating, then uniform plating is achieved, but the structure becomes more complex
Solution Approach 1:
The auxiliary pattern is designed to serve multiple functions simultaneously: it acts as an electrode for electrolytic plating to ensure uniform thickness of the spiral pattern, and it creates the recessed part structure that enhances adhesion between the sealing resin and coil part. This multi-functionality reduces the need for separate structures and minimizes overall complexity.
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 configuration improves adhesion between the sealing resin layer and the coil part, preventing peeling and enhancing the reliability and durability of the coil component by utilizing the anchor effect and maintaining insulation performance.
Implementation Method 1
A part of the sealing resin layer can be made to bite in the side wall surfaces of the respective interlayer insulating layers of the coil part
Implementation Method 2
a coil part in which a plurality of conductor layers and a plurality of interlayer insulating layers are alternately laminated
Data Source
AI summary
A coil component is provided with a coil part in which a plurality of conductor layers and a plurality of interlayer insulating layers are alternately laminated; and a sealing resin layer that covers the coil part. The conductor layers each include a spiral pattern. The interlayer insulating layers each cover an upper surface and a side surface of the spiral pattern. The recessed part is formed in the side wall surface of the interlayer insulating layer. A part of the sealing resin layer is embedded in the recessed part.