Magnetic Powder Coil Structure to Prevent Electrode Plating Blur
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Solution Overview
Problem
The challenge in the development of coil components is the reliability deterioration due to plating blur during the formation of external electrodes, which hinders the achievement of smaller, thinner, and lighter designs.
Innovation Solution
A coil component is designed with a body comprising magnetic metal powder particles and an insulating resin, where a plating prevention film is applied to the exposed magnetic metal powder particles, preventing plating blur and ensuring electrical insulation while maintaining magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If external electrodes are formed using a plating process to reduce component thickness, then the component thickness is reduced, but plating blur occurs due to exposed magnetic metal powder particles causing reliability deterioration
Solution Approach 1:
An insulating resin layer is introduced as an intermediary substance between the exposed magnetic metal powder particles and the plating process. This resin layer prevents direct contact between the plating solution and magnetic particles, eliminating plating blur while maintaining the thin-profile design. The resin acts as a protective mediator that allows the plating process to proceed without contamination.
Solution Approach 2:
The insulating resin is selectively applied only to regions where magnetic metal powder particles are exposed on the component surface, rather than coating the entire component. This localized treatment prevents plating blur at critical areas while maintaining overall component thinness and minimizing additional thickness from the resin layer.
2Reliability
If magnetic metal powder particles are exposed on the surface to maintain magnetic properties, then magnetic functionality is preserved, but plating blur occurs during external electrode formation
Solution Approach 1:
The insulating resin serves as a mediator that allows both magnetic functionality and plating precision to coexist. It covers exposed magnetic particles to prevent plating solution adhesion, while the underlying magnetic particles remain intact and functional. The resin creates a selective barrier that preserves magnetic properties in the bulk while preventing surface contamination.
Solution Approach 2:
The insulating resin is applied locally only to exposed magnetic particle regions, leaving other areas unaffected. This localized approach maintains magnetic functionality in the core material while precisely preventing plating defects only where needed, thereby preserving both magnetic performance and plating accuracy.
3Volume of moving object
If the component is designed to be smaller and thinner, then device integration is improved, but plating blur becomes more problematic due to reduced tolerance
Solution Approach 1:
The insulating resin intermediary provides a robust solution that works effectively at smaller scales. By preventing plating solution contact at the molecular level through the resin barrier, the solution eliminates plating blur regardless of component size, enabling reliable miniaturization without compromising plating precision.
Solution Approach 2:
The insulating resin forms a thin film layer on the component surface that is optimized for small-scale applications. This thin protective film provides sufficient barrier function to prevent plating blur while adding minimal thickness, making it ideal for miniaturized components where space is constrained.
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
This solution effectively prevents plating blur, enhances the reliability of the coil component, and allows for the creation of smaller, thinner, and lighter designs by using a plating prevention film that contains metal ions of the magnetic metal powder particles, thereby improving the component's electrical insulation and magnetic properties.
Implementation Method 1
the external electrodes may be formed using a plating process... the magnetic metal powder particle exposed from the surface of the body may cause plating blur
Data Source
AI summary
A coil component includes a body including magnetic metal powder particles and an insulating resin; a coil portion embedded in the body; and first and second external electrodes respectively disposed on the body to be spaced apart from each other and respectively connected to both end portions of the coil portion. A magnetic metal powder particle exposed from a surface of the body, among the magnetic metal powder particles, has a plating prevention film formed on at least a portion of a surface thereof and containing metal ions of the exposed magnetic metal powder particle.