Magnetic Coil Component Insulation Structure to Prevent Post Peeling
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Solution Overview
Problem
The insulation performance between the conductor post and the magnetic element body is insufficient in coil components due to direct contact, and the difference in thermal expansion coefficients leads to the risk of peeling, especially when magnetic fillers with large particles are present.
Innovation Solution
A coil component with a magnetic element body made of resin containing magnetic particles, featuring a conductor post embedded in the body with a first insulating layer between it and the magnetic element body, and a second insulating layer between the coil part and the magnetic element body, ensuring insulation and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductor post directly contacts the magnetic element body, then the manufacturing process is simplified, but the insulation performance becomes insufficient and peeling risk increases
Solution Approach 1:
An insulating layer is introduced as an intermediary substance between the conductor post and the magnetic element body. This insulating layer serves as a mediator that prevents direct contact while maintaining the structural integrity and electrical insulation requirements, thereby resolving the contradiction between manufacturing simplicity and insulation performance.
Solution Approach 2:
The patent employs composite material structure where the magnetic element body is formed by combining resin material with magnetic particles. This composite approach allows the magnetic element body to maintain its magnetic properties while the resin component provides the necessary insulation when combined with the insulating layer, addressing both electrical insulation and magnetic functionality requirements.
2Device complexity
If the conductor post directly contacts the magnetic element body, then the device structure is simplified, but the risk of peeling increases due to thermal expansion coefficient difference
Solution Approach 1:
The insulating layer acts as a buffer and intermediary between the conductor post and magnetic element body, absorbing thermal expansion differences and preventing direct mechanical stress transmission at the interface. This mediator layer maintains interface stability despite the thermal expansion coefficient mismatch between metal conductor and magnetic material.
Solution Approach 2:
The insulating layer is applied in advance to the conductor post before assembly with the magnetic element body. This beforehand cushioning prevents direct contact and anticipates the thermal expansion issues, providing a protective barrier that prevents peeling before it can occur during thermal cycling or operation.
3Reliability
If magnetic filler with large particle size is present on the conductor post surface, then the magnetic performance is enhanced, but gaps occur between the conductor post and magnetic element body causing peeling
Solution Approach 1:
The insulating layer serves as an intermediary that compensates for surface irregularities caused by large magnetic filler particles. It fills in the gaps and creates a uniform bonding surface, maintaining both the magnetic performance benefits of large particles and the mechanical bonding strength required to prevent peeling.
Solution Approach 2:
The insulating layer changes the surface parameters of the conductor post by providing a smooth, uniform outer surface that eliminates gaps caused by large magnetic filler particles. This parameter change in surface topology maintains the magnetic properties while improving the mechanical and electrical interface characteristics.
Data Source
AI summary
A coil component has a magnetic element body made of resin containing magnetic particles, a coil part embedded in the magnetic element body, conductor posts which are embedded in the magnetic element body and whose one ends are connected to the coil part and the other ends are exposed from the magnetic element body, an insulating layer interposed between the conductor posts and the magnetic element body, and other insulating layers interposed between the coil part and the magnetic element body. Since the insulating layer is interposed between the conductor posts and the magnetic element body, it is possible to ensure insulation performance between the conductor posts and the magnetic element body and to prevent the occurrence of peeling therebetween.