Electronic Component Coating Film Moisture Resistance
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Solution Overview
Problem
Existing electronic components with metal magnetic powder insulators face insufficient moisture resistance and chemical resistance due to thin phosphate chemical conversion coatings, which affect their quality and reliability.
Innovation Solution
A method involving a resin coating film containing cations of the metal magnetic powder elements, specifically using a resin emulsion with etching components like hydrofluoric acid, anionic surfactants with sulfonic acid groups, and oxidizing agents to form a thicker, more durable coating that selectively attaches to the metal magnetic powder, avoiding the inner conductor and ensuring continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a phosphate chemical conversion treatment is used for rust prevention, then the metal magnetic powder is protected, but the coating film becomes thin and moisture resistance and chemical resistance are insufficient
Solution Approach 1:
The patent uses a composite coating film comprising a phosphate conversion layer and a resin coating layer. The phosphate layer provides rust prevention while the resin layer (containing polyurethane, acrylic, or epoxy resin) provides thickness, moisture resistance, and chemical resistance. This composite structure resolves the contradiction by combining the advantages of both coating types.
Solution Approach 2:
The patent merges two coating processes into a single integrated system: the phosphate chemical conversion treatment and the resin coating application. The resin coating is applied over the phosphate-converted surface, creating a unified protective system that delivers both corrosion protection and environmental resistance with sufficient film thickness.
2Reliability
If a phosphate chemical conversion treatment is used, then rust prevention is achieved, but chemical resistance is insufficient
Solution Approach 1:
The composite coating system combines phosphate conversion coating (for rust prevention) with a chemically resistant resin layer. The resin layer acts as a chemical barrier while the phosphate layer provides substrate protection, achieving superior chemical resistance without complicating the manufacturing process significantly.
Solution Approach 2:
The phosphate chemical conversion treatment is performed as a preliminary step before applying the resin coating. This preliminary action creates a suitable surface for resin adhesion and ensures rust prevention is established before the final chemical resistance layer is applied, streamlining the overall manufacturing process.
3Area of stationary object
If a coating film is formed on the inner conductor, then coverage is achieved, but the continuity between the inner conductor and outer electrode is degraded
Solution Approach 1:
The coating is applied selectively to specific areas rather than uniformly across all surfaces. The resin coating is applied to the insulator body and metal magnetic powder surfaces, but the inner conductor surfaces that require electrical continuity are either excluded from coating or use coating formulations that maintain conductivity, ensuring local quality differentiation between insulating and conducting areas.
Solution Approach 2:
The patent uses the insulator body as an intermediary structure that separates the coating application areas from the electrical conduction paths. The resin coating is applied to the insulator and metal magnetic powder, while the inner conductor maintains its conductivity through the insulator structure, preventing direct coating interference with electrical continuity.
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 electronic components with enhanced moisture resistance, chemical resistance, and improved reliability by forming a thicker, more effective coating that protects the insulator and maintains conductor continuity.
Implementation Method 1
preparing a resin emulsion containing an etching component for ionizing a metal constituting the metal magnetic powder
Implementation Method 2
an etching component for ionizing a metal constituting the metal magnetic powder
Implementation Method 3
an anionic surfactant with a sulfonic acid group
Implementation Method 4
the resin emulsion further contains an oxidizing agent serving as an etching-facilitation component
Data Source
AI summary
An electronic component includes a main body composed of an insulator, a coating film covering the main body, a circuit element located inside the main body, and outer electrodes. The insulator contains a metal magnetic powder. The coating film is composed of a resin and a cationic element contained in the insulator.