Inductor Component With Oxidized Side Surface Regions
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Solution Overview
Problem
Conventional inductor components face issues with decreased element body strength and inductance due to oxidized metal magnetic powder expansion, which can lead to short circuits with other electronic components.
Innovation Solution
The inductor component design incorporates a side surface with both oxidized and non-oxidized regions of magnetic powder, where the oxidized region increases electric resistance to prevent short circuits and the non-oxidized region maintains strength and inductance, with the magnetic powder in direct contact with a resin to enhance bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal magnetic powder is oxidized to prevent short circuits, then the electric resistance increases and short circuit prevention is improved, but the element body strength decreases and inductance decreases
Solution Approach 1:
The patent applies local quality by creating distinct oxidized and non-oxidized regions on the side surface of the element body. The oxidized region (with oxide film) provides high electric resistance for short circuit prevention, while the non-oxidized region maintains strong magnetic powder-resin contact for structural strength and inductance. This spatial differentiation of oxidation states allows simultaneous achievement of both short circuit prevention and mechanical strength.
Solution Approach 2:
The side surface is segmented into functionally distinct zones: an oxidized region for electrical insulation and a non-oxidized region for mechanical bonding. This segmentation allows each region to optimize its specific function without compromising the other, resolving the contradiction between electrical resistance and structural strength.
2Reliability
If the metal magnetic powder is oxidized to prevent short circuits, then the electric resistance increases and short circuit prevention is improved, but the inductance decreases
Solution Approach 1:
By limiting oxidation to only the oxidized region on the side surface while maintaining non-oxidized magnetic powder in the non-oxidized region, the patent preserves the magnetic properties and inductance contribution of the non-oxidized magnetic powder while still providing short circuit prevention through the oxidized region.
3Productivity
If the mounting density is increased to improve productivity, then the output per time increases, but the distance between components is shortened and short circuit risk increases
Solution Approach 1:
The oxidized region on the side surface provides self-service electrical insulation that actively prevents short circuits between adjacent high-density mounted components. This self-insulating feature enables higher mounting density without proportionally increasing short circuit risk, as each component's oxidized side surface independently provides protection.
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 effectively suppresses short circuits and maintains the strength and inductance of the inductor component, even at increased mounting densities, by controlling the oxidation of the magnetic powder and its contact with the resin.
Implementation Method 1
the side surface has an oxidized region in which an oxide film formed by oxidizing a plurality of magnetic powders is exposed
Implementation Method 2
it is possible to suppress the short circuit by increasing an electric resistance of the magnetic powder by the oxidized region provided on the side surface of the element body
Data Source
AI summary
An inductor component includes an element body that includes magnetic powder and has first and second principal surfaces, and a side surface connecting the principal surfaces; an inductor wire in the element body; a first vertical wire that is in the element body, is connected to a first end of the inductor wire, and extends to the first principal surface; a second vertical wire that is in the element body, is connected to a second end of the inductor wire, and extends to the first principal surface; a first external terminal that is connected to the first vertical wire and is exposed on the first principal surface; and a second external terminal that is connected to the second vertical wire and is exposed on the first principal surface. The magnetic powder contains an Fe element as a main component, and the side surface has oxidized and non-oxidized regions.