Composite Coil Component Structure for Moisture and Voltage Resistance
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Solution Overview
Problem
Existing coil components face challenges with moisture resistance and voltage resistance due to high void content in sintered magnetic materials, which can lead to deterioration and short-circuit defects.
Innovation Solution
A coil component design featuring a first magnetic portion with a low resin content and a second magnetic portion with a higher resin content, where the second portion is disposed on the surface of the first portion, reducing voids and enhancing moisture and voltage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sintered body of metal magnetic particles is used as a magnetic material, then magnetic characteristics are achieved, but moisture resistance deteriorates due to high void content
Solution Approach 1:
The invention changes the resin content parameter in the second magnetic portion (higher resin content) compared to the first magnetic portion (lower resin content). This parameter differentiation reduces void content in the surface region while maintaining magnetic characteristics, thereby improving moisture resistance without sacrificing magnetic performance.
Solution Approach 2:
The invention uses a composite structure with two different magnetic portions having different resin contents. The first magnetic portion contains metal magnetic particles with lower resin content for magnetic performance, while the second magnetic portion contains magnetic particles and resin with higher resin content to reduce voids and improve moisture resistance, creating a composite material system that addresses both requirements.
2Reliability
If a sintered body of metal magnetic particles is used, then magnetic characteristics are achieved, but voltage resistance deteriorates due to high void content allowing plating solution ingress
Solution Approach 1:
The invention changes the resin content parameter in the second magnetic portion to be higher than in the first magnetic portion. This reduces void content in the surface region where plating solutions could penetrate, thereby preventing plating solution ingress and improving voltage resistance while maintaining magnetic characteristics through the first magnetic portion.
Solution Approach 2:
The composite structure with two magnetic portions having different resin contents creates a barrier effect. The second magnetic portion with higher resin content acts as a protective layer that prevents plating solution from penetrating into the voids, thereby improving voltage resistance while the first magnetic portion maintains the magnetic characteristics.
3Reliability
If resin content is increased to reduce voids and improve moisture resistance, then moisture resistance improves, but magnetic characteristics may deteriorate
Solution Approach 1:
The invention applies different resin contents to different regions: the first magnetic portion has lower resin content to maintain magnetic characteristics, while the second magnetic portion has higher resin content to reduce voids and improve moisture resistance. This local differentiation allows each region to optimize for its specific function without compromising the other.
Solution Approach 2:
The composite structure with two magnetic portions having different resin contents allows the system to achieve both goals: the first magnetic portion maintains magnetic characteristics with lower resin content, while the second magnetic portion improves moisture resistance with higher resin content, creating a synergistic composite material system.
Data Source
AI summary
A coil component including a substantially rectangular parallelepiped first magnetic portion that includes a coil conductor and a second magnetic portion disposed on at least the upper surface of the first magnetic portion. The first magnetic portion contains first magnetic particles including a metal magnetic material, the second magnetic portion contains second magnetic particles and a resin, and the resin content in the second magnetic portion is higher than the resin content in the first magnetic portion.