Coil Component Resin Wall Plating Uniformity
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Solution Overview
Problem
Conventional coil components with air core coils face issues of insulation deterioration due to narrowed winding intervals, leading to uneven plating growth and changes in thickness, which can compromise reliability and insulation properties.
Innovation Solution
A coil component design featuring a board with resin walls that separate the winding parts of the coil, allowing uniform plating growth and preventing thickness changes, where the resin walls are strategically positioned to maintain a predetermined distance from the seed parts, ensuring symmetrical and stable plating growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plating growth is used to form the coil, then the coil can be manufactured with good conductivity, but the winding interval is narrowed and insulation property deteriorates
Solution Approach 1:
The patent divides the coil structure into distinct segments by introducing resin walls that separate adjacent winding parts. These resin walls create physical segmentation that maintains insulation between windings while allowing the plating process to proceed independently in each segment, thus resolving the contradiction between manufacturing ease and insulation property.
Solution Approach 2:
The resin walls act as intermediary elements between the conductive plating layers and the insulation structure. These intermediaries provide the necessary insulation barrier while allowing the plating process to continue, thus maintaining both manufacturing simplicity and insulation reliability.
2Productivity
If plating growth is used to form the coil, then the coil can be manufactured efficiently, but the winding part becomes inclined and thickness changes occur
Solution Approach 1:
The resin walls are prepared and positioned in advance before the plating growth process begins. This preliminary action creates predetermined boundaries that guide the plating growth, ensuring uniform thickness distribution and preventing inclination of the winding parts while maintaining manufacturing efficiency.
Solution Approach 2:
The patent changes the physical parameters of the plating environment by introducing resin walls that modify the growth space and constraints. This parameter change controls the plating thickness uniformity and prevents inclination, thus resolving the contradiction between productivity and manufacturing precision.
3Reliability
If resin walls are added to ensure insulation, then insulation reliability improves, but device complexity increases
Solution Approach 1:
The resin walls serve multiple functions simultaneously: they provide insulation between windings, control plating growth uniformity, prevent thickness variations, and maintain structural integrity. This multi-functionality reduces the need for additional separate components, thus improving reliability without proportionally increasing device complexity.
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 design achieves reliable insulation and prevents thickness variations in the winding parts, enhancing the coil's structural integrity and insulation properties while maintaining sufficient bonding force and preventing peeling, thus improving the overall performance and reliability of the coil component.
Implementation Method 1
The aforementioned air core coil is formed by causing a plating growth of a conductor material such as Cu on a seed pattern provided on the board
Data Source
AI summary
A coil component in which a change in thicknesses of the winding part is prevented is provided. According to the coil component, since each of a pair of neighboring resin walls and a seed part between the pair of resin walls are separated by a predetermined distance, a plating part grown on the seed part is easy to grow uniformly between the pair of neighboring resin walls. For this reason, the winding part whose surface is gentle and in which a change in thickness is prevented is obtained by plating growth.