Electronic Component Coating Film Adhesion and Corrosion Resistance
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Solution Overview
Problem
The existing electronic components with metal magnetic powder and insulating resin coatings face issues with terminal electrodes peeling off from the insulator, leading to poor adhesion and increased risk of corrosion.
Innovation Solution
An electronic component with a coating film containing metal cations and inorganic particles is developed, where the coating film is formed using a mixed solution with an ionizing component, anionic surfactant, and resin, and inorganic particles are dispersed to enhance adhesion of outer electrodes to the coating film, ensuring firm contact and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical conversion treatment with phosphate is applied to form an insulating coating film on metal magnetic powder, then rust prevention is improved, but terminal electrode adhesion deteriorates
Solution Approach 1:
The coating system is segmented into multiple functional layers: an insulating coating film layer (providing rust prevention) and an outer electrode adhesion promotion layer (providing strong bonding). This segmentation allows each layer to specialize in its function without compromising the other, resolving the contradiction between rust prevention and electrode adhesion.
Solution Approach 2:
The patent uses composite coating materials comprising both insulating properties (for rust prevention) and adhesion-promoting properties (for electrode bonding). The composite structure integrates different material characteristics to simultaneously achieve corrosion resistance and strong electrode attachment.
2Reliability
If an insulating coating film is formed on the insulator surface, then insulation is improved, but outer electrode contact firmness deteriorates
Solution Approach 1:
The coating system is divided into distinct functional layers: an insulating coating film layer that provides electrical insulation, and an outer electrode adhesion promotion layer that ensures firm electrode contact. This layered segmentation allows simultaneous achievement of insulation and strong electrode attachment.
Solution Approach 2:
Different regions of the coating system have different properties: the insulating coating film provides electrical insulation where needed, while the adhesion promotion layer provides bonding capability at the electrode interface. This local differentiation of material properties resolves the contradiction between insulation and contact firmness.
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 solution provides enhanced adhesion of outer electrodes, improved insulation, and increased resistance to corrosion and moisture, preventing peeling and corrosion of the metal magnetic powder, thus ensuring the electronic component's reliability and performance.
Implementation Method 1
a mixed solution containing an ionizing component for ionizing a metal constituting the above-described metal magnetic powder
Implementation Method 2
coating the above-described main body with the above-described mixed solution and performing drying
Implementation Method 3
inorganic particles adhering to the surface of the above-described coating film
Data Source
AI summary
An electronic component includes a main body made from a metal magnetic powder and an insulating resin, a coating film covering the surface of the main body, a conductor disposed inside the main body, inorganic particles adhering to the surface of the coating film, and outer electrodes which are electrically connected to the conductor and which cover portions of the surface of the coating film while inorganic particles adhere to the portions, wherein the coating film contains a resin and metal cations.