Inductor Electrode Bonding Structure for Vibration Reliability
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Solution Overview
Problem
Conventional inductors face reliability issues due to weak connections between the electrode member and the magnetic core, particularly when the inductor size increases, leading to decreased vibration resistance and connection reliability.
Innovation Solution
The inductor design incorporates a magnetic core with a conductive coil buried inside, an electrode member electrically connected to the coil, and a dual adhesive system where the first adhesive is between the electrode member and the magnetic core's bottom surface, and the second adhesive is at the corner between the side surface and the electrode member's projecting portion, enhancing the connection strength and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the inductor size is increased, then the power supply capacity is improved, but the connection reliability between the electrode member and the magnetic core deteriorates
Solution Approach 1:
The adhesive application is segmented into two distinct locations: the first adhesive is applied at the bottom surface between the electrode member and magnetic core, while the second adhesive is applied at the corner between the side surface and electrode member. This segmentation allows each adhesive to perform its specific function optimally, with the bottom adhesive providing primary bonding and the corner adhesive providing additional reinforcement against detachment.
Solution Approach 2:
Different adhesive application locations are used to address different stress points: the bottom surface adhesive addresses the primary connection need, while the corner adhesive specifically addresses the vulnerability at the edge where detachment is more likely to occur. This local quality approach ensures that adhesive is applied where it is most needed based on the local stress and detachment risks.
2Device complexity
If a single adhesive location is used, then the device complexity is reduced, but the vibration resistance deteriorates
Solution Approach 1:
The adhesive application is divided into two distinct locations: the first adhesive at the bottom surface and the second adhesive at the corner. This segmentation provides comprehensive vibration resistance by securing the electrode member at multiple points, preventing detachment that would occur with a single adhesive location while maintaining relatively simple application procedures.
3Reliability
If the electrode member is firmly fixed to the magnetic core, then the connection reliability is improved, but the heat dissipation during soldering deteriorates
Solution Approach 1:
Instead of applying adhesive over the entire contact surface between the electrode member and magnetic core, the adhesive is applied only at specific locations (bottom surface and corner). This partial action provides sufficient connection reliability to prevent detachment while leaving most of the contact surface free for heat dissipation during soldering, thus resolving the contradiction between firm fixation and heat dissipation.
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 significantly improves the reliability and vibration resistance of the inductor by ensuring a strong and stable connection between the magnetic core and the electrode member, even when the inductor size is increased, and facilitates easier soldering by absorbing heat effectively during reflow soldering.
Implementation Method 1
a first adhesive containing an adhesive resin material and adhering the magnetic core and the electrode member to each other
Implementation Method 2
a second adhesive containing an adhesive resin material and adhering the magnetic core and the electrode member to each other at a position different from the first adhesive
Data Source
AI summary
An inductor includes: a magnetic core including a bottom surface, a top surface, and a side surface; a coil element including a coil portion buried in the magnetic core; an electrode member located outside of the magnetic core and electrically connected to the coil element; a first adhesive adhering the magnetic core and the electrode member; and a second adhesive adhering the magnetic core and the electrode member at a position different from the first adhesive. The electrode member includes a first bottom plate portion overlapping the bottom surface, and a second bottom plate portion connected to the first bottom plate portion and projecting from the side surface. The first adhesive is located between the first bottom plate portion and the bottom surface. The second adhesive is located at a corner between an edge of the side surface on the bottom surface side and the second bottom plate portion.