Embedded Coil Conductor Resin Shielding Against Pressure Shorts
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Solution Overview
Problem
Existing coil components with embedded coil conductors in magnetic portions are prone to short circuits when external pressure is applied, as the magnetic metal powder can deform or pierce the insulating film, leading to electrical failures.
Innovation Solution
A coil component design featuring a magnetic portion with metal magnetic particles and resin, where the coil conductor is embedded with insulating film and protected by resin portions on its surfaces and gaps, preventing deformation or piercing of the insulating film under pressure, and a manufacturing method involving the embedding of a wound conductive wire with insulating film and forming outer electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil conductor is covered with an insulating film only, then the manufacturing process is simple, but the insulating film may deform or pierce under external pressure causing short circuits
Solution Approach 1:
A resin portion is provided on the surface of the coil conductor before embedding it in the magnetic portion. This preliminary protective layer prevents the insulating film from being deformed or pierced by metal magnetic particles during subsequent manufacturing processes or operation, thereby preventing short circuits without requiring complex multi-layer insulation structures
Solution Approach 2:
The resin portion acts as an intermediary protective layer between the insulating film and the metal magnetic particles in the magnetic portion. This intermediate layer absorbs the mechanical stress and prevents direct contact between the insulating film and sharp metal particles, eliminating the need for thicker or multi-layer insulating films
2Reliability
If the coil conductor is embedded directly in the magnetic portion, then the manufacturing process is simple, but metal magnetic particles can deform or pierce the insulating film under pressure
Solution Approach 1:
The resin portion is applied to the coil conductor surface before the embedding process. This preliminary protection ensures that during the embedding process and subsequent operations, the insulating film cannot be pierced even if metal magnetic particles come into contact with the coil conductor under external pressure
Solution Approach 2:
The resin portion provides beforehand cushioning protection to the insulating film. When external pressure is applied during manufacturing or operation, the resin portion absorbs and distributes the pressure, preventing it from concentrating on the insulating film and causing deformation or piercing
Data Source
AI summary
A coil component including a body having a magnetic portion including a metal magnetic particle and a resin, and a coil conductor embedded in the magnetic portion, and an outer electrode provided on a surface of the body and connected to the coil conductor. The coil conductor is a wound body of a conductive wire covered with an insulating film, and has a first surface and a second surface facing each other in a winding axis direction. Also, on the first surface of the coil conductor, a first resin portion is provided at least either on a surface of the conductive wire or in a gap between adjacent ends of the conductive wire.