Electronic Component Body with Exposed Magnetic Particles
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Solution Overview
Problem
Existing electronic components, such as molded coils, face issues with insufficient adhesion between the body and the outer electrode, leading to potential electrical connectivity problems and reduced reliability.
Innovation Solution
An electronic component with a body made of a material containing particles of a metallic magnetic material, where the outer electrode is formed on a surface with exposed particles of the metallic magnetic material, enhancing the contact area and adhesion through an anchor effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coil is sealed with a molding magnetic resin in which a resin and magnetic powder are mixed, then the coil is protected and enclosed, but the adhesion between the body and the outer electrode becomes insufficient
Solution Approach 1:
The patent applies local quality by creating a contact portion with different properties from the main body. The contact portion has exposed metallic magnetic material particles that provide enhanced adhesion for the outer electrode, while the rest of the body maintains its original molding magnetic resin composition. This localized modification solves the adhesion problem without requiring complete redesign of the entire manufacturing process.
Solution Approach 2:
The patent uses preliminary action by forming the groove and exposing the metallic magnetic material particles before applying the outer electrode. This preparatory step ensures that the surface is pre-treated with high-adhesion characteristics, allowing the outer electrode to bond effectively to the exposed particles rather than requiring additional adhesion promoters or complex surface treatments.
2Area of stationary object
If the surface is modified to improve adhesion, then the contact area with the outer electrode increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the body surface into two distinct regions: the main body surface and the contact portion. The contact portion is created as a separate functional area with a groove structure that exposes the metallic magnetic material particles. This segmentation allows the contact area to be optimized for adhesion while keeping the rest of the body simple, and the groove formation can be integrated into existing manufacturing processes.
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 improved adhesion between the body and the outer electrode results in enhanced electrical connectivity and reduced size requirements for the electronic component, allowing for downsized designs without compromising performance.
Implementation Method 1
The surface of the body has a contact portion with which the outer electrode is in contact, and the contact portion includes particles of the metallic magnetic material which are exposed from the surface of the body
Data Source
AI summary
An electronic component includes a body made of a material containing particles of a metallic magnetic material, and an outer electrode disposed on a surface of the body. The surface of the body has a contact portion with which the outer electrode is in contact, and the surface of the body includes particles of the metallic magnetic material which are exposed from the surface of the body.