Multilayer Coil Component Structure for Firing Shrinkage Matching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components face issues with cracking and chipping due to differences in firing shrinkage behavior between oxide magnetic layers and insulating layers, particularly when the coil conductor is produced by a plating method, as the locations and volumes of insulating layers with a glass component are not optimized.
Innovation Solution
A coil component design that includes a specific stacking sequence of magnetic and insulating bodies with optimized volume ratios between the first outer insulator, second outer insulator, inner insulator, coil, and magnetic bodies, where 0.05≤A≤0.07, 0.2≤B≤0.4, 0.01≤C≤0.08, 0.03≤D≤0.05, and 0.4≤E≤0.71, with C≤0.2B and A+B+C+D+E=1, to minimize differences in firing shrinkage behavior and prevent cracking and chipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If insulating layers containing glass component are simply interposed between oxide magnetic layers, then the structure is simplified, but cracking and chipping occur due to mismatched firing shrinkage behavior
Solution Approach 1:
The patent changes the parameters of the insulating layers containing glass component, specifically adjusting their locations and volumes relative to the first and second insulating layers based on the proportion of coil conductor included. This parameter adjustment ensures that the firing shrinkage behavior of oxide magnetic layers matches that of the insulating layers, preventing cracking and chipping while maintaining structural simplicity
Solution Approach 2:
The patent applies local quality by making the insulating layers containing glass component have different locations and volumes in different regions, specifically adjusted in accordance with the proportion of coil conductor included in the first and second insulating layers. This localized adjustment optimizes firing shrinkage matching at each interface, preventing defects without requiring complete redesign of the entire structure
2Ease of manufacture
If the volume ratios of insulating layers and magnetic layers are not optimized, then manufacturing is simpler, but firing shrinkage mismatch causes cracking and chipping
Solution Approach 1:
The patent specifies optimized volume ratios parameters: 0.05≤A≤0.07 for first outer insulator, 0.2≤B≤0.4 for inner insulator, 0.4≤E≤0.71 for magnetic bodies, with additional constraints C≤0.2B and A+B+C+D+E=1. These parameter specifications provide clear manufacturing targets that balance simplicity with precision, ensuring firing shrinkage matching without overly complex manufacturing procedures
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
The optimized volume ratios effectively suppress occurrences of cracking and chipping, improve high-frequency impedance characteristics, and enhance the insulating properties of the coil component, reducing the risk of peeling and moisture entry.
Implementation Method 1
the firing shrinkage behavior of the oxide magnetic layers composed of a material different from the first insulating layer approaches the firing shrinkage behavior of the first insulating layer
Data Source
AI summary
A coil component includes a first outer magnetic body, a first outer insulator, a first inner magnetic body, an inner insulator, a second inner magnetic body, a second outer insulator, and a second outer magnetic body stacked sequentially, and a coil in the inner insulator and an internal magnetic body inside the coil. Volumes A, B, C, and D of the first and second outer insulators, the inner insulator, the coil, and the internal magnetic body, respectively, and volume E of the first outer magnetic body, the first inner magnetic body, the second inner magnetic body, and the second outer magnetic body satisfy 0.05≤A≤0.07, 0.2≤B≤0.4, 0.01≤C≤0.08, 0.03≤D≤0.05, and ≤0.4≤E≤0.71, where 0.05B≤C≤0.2B and A+B+C+D+E=1.