Coil Component Surface Metal Layer Bonding
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Solution Overview
Problem
The existing coil components face issues with coupling force between the body and external electrodes, as well as contact resistance, which can lead to reduced breakdown voltage and bonding strength.
Innovation Solution
A coil component design incorporating a body with magnetic metal particles and an insulating resin, featuring a surface insulation layer with openings exposing lead-out portions and a connection metal layer formed by connecting magnetic metal particles, where the area of the metal component including the connection metal layer is 75% or more of the surface area, enhancing bonding strength and maintaining breakdown voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional body structure with coil portion is used, then the component structure is simple, but the coupling force between body and external electrode is insufficient
Solution Approach 1:
The body is constructed as a composite material consisting of magnetic metal particles dispersed in an insulating resin matrix. This composite structure provides both mechanical support and enhanced coupling force through the distributed magnetic particles, which create multiple contact points for the external electrode while maintaining structural integrity.
Solution Approach 2:
A connection metal layer is selectively formed in a specific region of the body surface where external electrodes are to be attached. This local metal layer increases the coupling force at the critical bonding interface without requiring the entire body structure to be complex, thus resolving the contradiction between localized performance enhancement and overall structural simplicity.
2Strength
If the body structure is modified to improve coupling force, then bonding strength increases, but breakdown voltage may be reduced
Solution Approach 1:
The connection metal layer is formed only in a specific region of the body surface rather than throughout the entire body. This localized approach enhances bonding strength at the electrode interface while preserving the insulating properties of the bulk material, thus maintaining breakdown voltage without sacrificing bonding strength.
Solution Approach 2:
The insulating resin matrix provides high breakdown voltage resistance while the dispersed magnetic metal particles and localized connection metal layer provide enhanced coupling force. The composite structure allows these two opposing requirements to be satisfied in different regions of the material system.
3Strength
If magnetic metal particles are connected to form connection metal layer, then coupling force increases, but manufacturing complexity increases
Solution Approach 1:
Magnetic metal particles are pre-dispersed in the insulating resin during body formation, creating a predetermined distribution pattern. The connection metal layer is then formed in a subsequent step only in the required region. This preliminary dispersion simplifies manufacturing by eliminating the need for complex post-assembly operations to create the metal connections.
Solution Approach 2:
The magnetic metal particles are transformed into a connection metal layer through controlled sintering or melting processes that change the physical state and connectivity of the particles. This parameter change (from discrete particles to connected layer) achieves enhanced coupling force through a relatively simple thermal processing step rather than complex assembly operations.
Data Source
AI summary
A coil component includes: a body including magnetic metal particles and an insulating resin; a coil portion disposed within the body and including a lead-out portion exposed to one surface of the body; a surface insulation layer disposed on the body and having an opening exposing each of at least a portion of the lead-out portion and at least a portion of the one surface of the body; and an external electrode disposed in the opening and connected to the lead-out portion, wherein a connection metal layer in which at least some of the magnetic metal particles are connected to each other is disposed in a region of the one surface of the body, exposed in the opening, and an area of a metal component including the connection metal layer in the region is 75% or more of an area of the region.