Inductor Protective Film Composition for Moisture and Corrosion Resistance
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Solution Overview
Problem
Existing coil components have room for improvement in the quality of their protective layers, which affect the overall performance and reliability of the inductor.
Innovation Solution
An inductor with a body containing soft magnetic powder and resin, a coil embedded in the body, outer electrodes on the body, and a protective film on the surface of the body. The protective film has a thickness of 10 μm or more and is composed of silica particles and resin, with silica particles having an average diameter of 15 nm to 75 nm and a weight percentage of silica particles to resin between 150% and 250%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is applied to the coil component, then protection against moisture and corrosion is improved, but the quality of the protective layer is insufficient
Solution Approach 1:
The patent changes the parameters of the protective layer by specifying a thickness of 10 μm or more and controlling the silica particle size (15-75 nm average diameter) and silica-to-resin weight ratio (150%-250%). These parameter adjustments resolve the contradiction by achieving both adequate protection and high quality through precise control of physical and chemical properties.
Solution Approach 2:
The protective layer is formed as a composite material containing silica particles dispersed in resin. This composite structure combines the protective properties of silica with the binding properties of resin, achieving both moisture/corrosion resistance and high layer quality through material composition optimization.
2Reliability
If the protective film thickness is increased to improve protection, then protection quality is improved, but manufacturing complexity increases
Solution Approach 1:
By setting the thickness parameter at 10 μm or more and controlling the silica particle size and concentration parameters, the patent achieves effective protection without excessive thickness. This resolves the contradiction by finding the optimal parameter range that provides sufficient protection while maintaining manufacturability.
Data Source
AI summary
An inductor includes a body containing soft magnetic powder and resin, a coil embedded in the body, outer electrodes on the body, and a protective film on the surface of the body. The protective film has a thickness of 10 μm or more and contains silica particles and resin. In the protective film, the silica particles have an average diameter of 15 nm to 75 nm, and the percentage by weight of the silica particles to the resin is between 150% and 250%.