Inductor Mark Layer Composition for Stable Co-Sintering
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Solution Overview
Problem
Conventional inductor components face challenges in achieving a favorable sintered state for both the mark layer and insulating layers due to the difference in firing temperatures caused by the addition of pigments in the mark layer, leading to inconsistent performance.
Innovation Solution
The inductor component incorporates a mark layer with a higher potassium abundance ratio than the insulating layers, using amorphous glass with pigments like Ti, Co, and Zr oxides, and quartz crystals, which allows for a synchronized sintering process and enhanced distinguishability through varying reflectance spectra, ensuring both layers achieve a favorable sintered state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pigment is added to the mark layer to differentiate its color from the insulating layers, then the directional alignment property is improved, but the firing temperature increases making it difficult to achieve a favorable sintered state for both layers simultaneously
Solution Approach 1:
The patent modifies the chemical composition parameters of the glass material in the mark layer by adjusting the ratio of specific oxides (increasing Al2O3 to 40-70 wt%, adjusting B2O3 to 10-30 wt%, SiO2 to 10-40 wt%, and adding 1-10 wt% of coloring oxide) to achieve a favorable sintered state at the firing temperature while maintaining color differentiation functionality
Solution Approach 2:
The mark layer is designed as a composite material consisting of glass powder (with specific oxide composition) and coloring oxide particles, where the glass matrix provides the sintering characteristics and the coloring oxide provides the color differentiation, allowing both functions to coexist
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 approach enables a stable and reliable sintered state for both the mark and insulating layers, improving the mechanical strength and insulation reliability while providing clear visual distinguishability for directional alignment and mechanical sorting.
Implementation Method 1
In a reflection spectrum for light having a wavelength of 380 nm or more and 780 nm or less, a maximum value of reflectance of the pigment of the intra-mark-layer crystal is greater than a maximum value of reflectance of the intra-insulating-layer crystal
Data Source
AI summary
An inductor component comprising an element body; a helically wound coil disposed in the element body; and an external electrode disposed in the element body and electrically connected to the coil. The element body includes a plurality of insulating layers and a mark layer constituting a portion of an outer surface of the element body, and a K abundance ratio (atom %) in the mark layer is higher than a K abundance ratio (atom %) in the insulating layers.