Coil Component Glass Surface Layer Adhesion
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Solution Overview
Problem
Existing coil components face challenges in achieving sufficient adhesion between internal and external cores due to insufficient wettability of ferrite materials and the limitations of epoxy resin impregnation, leading to degraded anchor effects and reduced adhesive strength, especially in compact configurations.
Innovation Solution
A coil component design featuring a glass surface layer on both the internal and external cores, with an inductive component wound over the internal core and terminal electrodes, utilizing UV curable resin and thermosetting resin for bonding, which enhances adhesion through capillary action and high mechanical strength, regardless of surface area or dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin is used as adhesive agent and impregnated into porous cores, then adhesive strength is improved through anchor effect, but insufficient curing occurs due to osmotic pressure difference causing curing agent impregnation first
Solution Approach 1:
A glass layer is introduced as an intermediary between the porous ferrite core and the epoxy resin adhesive. This glass layer has controlled porosity that allows the adhesive to impregnate effectively while preventing the curing agent from penetrating too deeply into the core, ensuring complete curing. The glass layer acts as a mediator that balances the conflicting requirements of adhesive impregnation and curing agent distribution.
2Reliability
If ferrite material is used for cores, then magnetic properties are achieved, but wettability against adhesive agent is insufficient requiring increased surface area
Solution Approach 1:
The glass layer is applied locally on the surface of the ferrite core where adhesive contact occurs. This creates a local quality change: the bulk ferrite maintains its magnetic properties while the surface glass layer provides improved wettability and controlled porosity for adhesive impregnation. This localized modification resolves the contradiction without changing the overall magnetic properties of the core.
3Strength
If surface area is increased to improve adhesive contact, then adhesive strength is improved, but coil component profile increases violating compact configuration requirement
Solution Approach 1:
The invention changes the porosity parameter of the glass layer to optimize adhesive impregnation. By controlling the pore size and distribution in the glass layer, sufficient adhesive contact is achieved with enhanced wettability, allowing strong bonding without increasing the surface area and thus maintaining a compact coil component profile.
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 glass surface layer improves wettability and stability of the adhesive, ensuring strong bonding between the cores, maintaining adhesion force even with porous ferrite materials, and allowing for a compact, low-profile coil component with enhanced rigidity and electrical insulation.
Implementation Method 1
utilizing UV curable resin and thermosetting resin for bonding, which enhances adhesion through capillary action and high mechanical strength
Implementation Method 2
utilizing UV curable resin and thermosetting resin for bonding
Data Source
AI summary
A coil component ensuring adhesive bonding between first and second cores. The coil component also includes an inductive component and a pair of terminal electrodes. The first core has a first adhesion surface. The second core is connected to the first core by an adhesive agent and has a second adhesion surface in confrontation with the first adhesion surface. At least one of the first adhesion surface and the second adhesion surface is formed of a glass surface layer to which the adhesive agent is applied. The inductive component is wound over the first core. The pair of terminal electrodes are provided at one of the first core and the second core. The inductive component has one end portion electrically connected to one of the terminal electrodes and has another end portion electrically connected to remaining one of the terminal electrodes.