Inductor Mark Layer Composition for Consistent 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 use of pigments in the mark layer, which require a higher firing temperature than the insulating layers, leading to inconsistent sintering.
Innovation Solution
The inductor component design includes insulating layers with a higher K abundance ratio and amorphous intra-insulating-layer crystals, and mark layers with amorphous intra-mark-layer crystals containing pigments, ensuring a favorable sintered state by matching the glass softening points and providing distinct reflectance for visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pigment is added to the mark layer to make its color different from the insulating layers, then the directional alignment property is improved, but the firing temperature must be increased which makes it difficult to achieve a favorable sintered state for both the mark layer and insulating layers simultaneously
Solution Approach 1:
The patent applies local quality by giving different chemical compositions to different layers: the mark layer contains a pigment and has a specific glass composition with SiO2 40-70 wt%, B2O3 10-30 wt%, and Al2O3 5-20 wt%, while the insulating layers have a different glass composition without pigment. This allows each layer to be optimized for its specific function - the mark layer achieves color differentiation and the insulating layers achieve proper sintering at matching temperatures.
Solution Approach 2:
The patent changes the chemical parameters of the glass composition in the mark layer compared to the insulating layers. Specifically, the mark layer glass contains SiO2 40-70 wt%, B2O3 10-30 wt%, and Al2O3 5-20 wt%, which are carefully controlled to match the softening point with the insulating layers while accommodating the pigment addition. This parameter optimization enables simultaneous favorable sintering of both layers.
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 achieves a stable sintered state for both mark and insulating layers, enhancing mechanical strength and insulation reliability while ensuring clear distinguishability for directional alignment and reducing manufacturing steps.
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
Implementation Method 2
a favorable sintered state can be achieved for both the mark layer and the insulating layers at the same time
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.