Coil Component Support Member Machined Surface Adhesion
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Solution Overview
Problem
Miniaturized power inductors face challenges with delamination due to adhesion issues between heterogeneous materials and increased magnetic material content, which reduces their efficiency and reliability.
Innovation Solution
A coil component design that includes a support member with a machined surface to improve adhesion and reduce delamination, featuring a body with a magnetic material and external electrodes, where the support member's thickness is reduced near the external electrodes and includes protrusions or a coplanar surface to increase inductance while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the content of magnetic material is increased to achieve high capacity and low RDC, then the inductance increases, but delamination occurs due to adhesion issues between heterogeneous materials
Solution Approach 1:
A support member is introduced as an intermediary component between the coil and the magnetic material. This support member provides a stable bonding surface that facilitates adhesion between the coil structure and the magnetic material, preventing delamination while allowing increased magnetic material content for higher inductance.
Solution Approach 2:
The support member features a machined surface at specific locations (where it contacts the external electrode) to enhance adhesion locally. This localized surface treatment improves bonding quality at critical interfaces without requiring changes to the entire structure, enabling reliable adhesion with increased magnetic material content.
2Area of stationary object
If the chip size is reduced for miniaturization, then the device becomes more compact, but the space for magnetic material is limited, reducing inductance
Solution Approach 1:
The support member is designed with varying thickness in the vertical dimension, being thinner at edges and thicker at the center. This dimensional variation allows the structure to fit within a compact chip footprint while maximizing the volume available for magnetic material in the central region, thereby maintaining inductance despite reduced overall chip size.
Solution Approach 2:
The support member with its coil and magnetic material is nested within the body structure. This nesting arrangement optimizes the use of available space, allowing the magnetic material to be positioned efficiently within the constrained chip dimensions while maintaining sufficient inductance.
3Reliability
If the support member thickness is reduced near external electrodes to improve adhesion, then delamination is reduced, but the structural strength may be compromised
Solution Approach 1:
The support member exhibits non-uniform thickness with local variations optimized for different functions: thinner regions at the edges where external electrodes contact to improve adhesion and reduce delamination, and thicker regions at the center to maintain structural strength and provide adequate space for magnetic material.
Data Source
AI summary
A coil component includes a body, including a coil and a support member supporting the coil, and an external electrode disposed on an external surface of the body. The coil component includes a machined surface formed on a boundary surface between a portion of the support member, removed in the vicinity of a junction portion between the external electrode and the coil, and the remainder of the support member. A cavity, from which the portion of the support member has been removed, is filled with a magnetic material, or an insulating layer is disposed in the cavity.