Coil Component Resin Layer With Spherical Fillers to Prevent Voids
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Solution Overview
Problem
Existing coil components face issues with voids forming around the coil pattern due to the use of magnetic particles with a high aspect ratio, which fail to conform to the irregularities of the insulating layer, leading to potential failures.
Innovation Solution
A coil component design featuring a coil pattern embedded in a first resin layer with spherical filler particles and a binder resin, sandwiched between the coil pattern and a magnetic body, ensuring the first surface of the seed part is exposed, thereby preventing voids and enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic particles with high aspect ratio are used to enhance magnetic characteristics, then magnetic properties are improved, but voids occur around wirings because the magnetic layer fails to follow irregularities on the insulating layer
Solution Approach 1:
The patent uses spherical filler particles instead of flat particles with high aspect ratio. The spherical shape allows the particles to conform to the irregularities of the coil pattern and insulating layer surface, preventing void formation while maintaining magnetic properties. The curved surface of spheres can adapt to surface variations better than flat particles.
Solution Approach 2:
The patent creates a composite magnetic layer combining spherical filler particles with binder resin. This composite structure allows the magnetic particles to be held together by the binder, forming a cohesive layer that can follow surface irregularities while maintaining magnetic characteristics. The binder resin fills gaps between spherical particles and adapts to surface variations.
2Reliability
If a magnetic layer is applied over the coil pattern, then magnetic properties are enhanced, but the layer cannot conform to surface irregularities, causing voids
Solution Approach 1:
Spherical filler particles can conform to surface irregularities better than flat particles, allowing the magnetic layer to follow the contours of the coil pattern and insulating layer. This reduces void formation and improves contact area, thereby enhancing adhesion strength between the magnetic layer and underlying structures.
Solution Approach 2:
The binder resin acts as an intermediary material between the spherical filler particles and the coil pattern. It provides adhesive bonding while allowing the magnetic layer to conform to surface irregularities, thus maintaining both adhesion strength and magnetic properties without void formation.
3Device complexity
If flat magnetic particles are used, then the magnetic layer structure is simple, but increasing aspect ratio causes the layer to fail to follow irregularities, creating voids
Solution Approach 1:
The patent transitions from flat particles to spherical filler particles. While spherical particles may seem more complex to manufacture, they provide superior conformity to surface irregularities. The spherical shape naturally adapts to surface variations without requiring complex layer structures, achieving better manufacturing precision in terms of void prevention.
Solution Approach 2:
The patent changes the shape parameter of filler particles from flat (high aspect ratio) to spherical. This parameter change fundamentally alters how the particles interact with surface irregularities, enabling conformal coverage without voids while maintaining a relatively simple single-layer magnetic structure.
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 configuration effectively prevents voids around the coil pattern, increases the strength and adhesion of the resin layer, reduces the overall thickness, and enhances magnetic properties while maintaining high inductance and permeability.
Implementation Method 1
a first resin layer positioned between the coil pattern and magnetic body and including spherical filler particles and binder resin
Implementation Method 2
The coil pattern is embedded in the first resin layer such that the first surface of the seed part is exposed from the first resin layer
Implementation Method 3
a magnetic body covering the coil pattern
Implementation Method 4
a coil pattern having a seed part including resin and having first and second surfaces positioned on mutually opposite sides, and a main body part made of a metal material and laminated on the second surface of the seed part
Data Source
AI summary
Disclosed herein is a coil component that includes: a coil pattern having a seed part including resin and having first and second surfaces positioned on mutually opposite sides, and a main body part made of a metal material and laminated on the second surface of the seed part; a magnetic body covering the coil pattern; and a first resin layer positioned between the coil pattern and magnetic body and including spherical filler particles and binder resin. The coil pattern is embedded in the first resin layer such that the first surface of the seed part is exposed from the first resin layer.