Multilayer Coil Interface Layout for Mounting Crack Resistance
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Solution Overview
Problem
Multilayer inductors experience cracking of the magnetic layer due to impact loads during mounting, primarily at the void portion between the magnetic and conductive layers, leading to stress concentration and potential damage.
Innovation Solution
A multilayer coil component design with a base body composed of stacked insulating and conductive layers, where at least one inner conductive layer is positioned between outer conductive layers, and a void layer is strategically omitted in certain interfaces to reduce stress concentration and prevent cracking, utilizing a specific manufacturing method involving magnetic and non-magnetic ferrite pastes and resin layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a void portion is provided between the magnetic layer and the conductive layer, then stress relaxation is achieved, but the magnetic layer may crack under impact load
Solution Approach 1:
The patent applies local quality by differentiating the void layer configuration between inner and outer interfaces. Void layers are provided at inner interfaces (between inner conductive layers and insulating layers) to relax stress, while deliberately omitted at outer interfaces (between outer conductive layers and insulating layers) to prevent crack initiation under impact load. This localized differentiation resolves the contradiction between stress relaxation and crack resistance.
2Stress or pressure
If void layers are provided at all interfaces, then stress is relaxed throughout the structure, but crack susceptibility increases at outer interfaces
Solution Approach 1:
The patent segments the interface structure into two distinct types: inner interfaces with void layers for stress relaxation, and outer interfaces without void layers for crack prevention. This segmentation allows the structure to simultaneously achieve stress distribution benefits while maintaining mounting durability by protecting critical outer surfaces from impact-induced cracking.
3Strength
If the multilayer structure is made more robust to prevent cracking, then structural integrity improves, but stress relaxation capability decreases
Solution Approach 1:
The patent implements local quality by providing void layers only at inner interfaces where stress relaxation is most beneficial, while maintaining solid structure at outer interfaces where mechanical strength and crack resistance are critical. This localized approach allows the structure to achieve both stress relief and structural integrity simultaneously, rather than having to compromise one for the other throughout the entire structure.
Data Source
AI summary
A multilayer coil component includes a base body, plural conductive layers, and plural outer electrodes. The base body include plural insulating layers stacked on each other in a stacking direction. The plural conductive layers are disposed inside the base body and are stacked on each other in the stacking direction together with the plural insulating layers. The plural outer electrodes are each disposed on a surface of the base body. The base body has first and second main surfaces opposing each other in the stacking direction. At least some of the plural conductive layers are electrically connected to each other so as to form a coil which is electrically connected to the plural outer electrodes. The plural conductive layers include first and second outer conductive layers and at least one inner conductive layer.