Inductor Component Resin Insulating Layer Gap Prevention
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Solution Overview
Problem
The existing inductor components face issues with gaps forming at the boundaries between the resin insulating layer and metal pins due to thermal contraction, which can lead to moisture ingress and positional deviations of columnar conductors, affecting the component's characteristics and reliability.
Innovation Solution
The inductor component incorporates a resin insulating layer with specific covering portions that form close contact with the metal pins, preventing gap formation and positional deviations, and includes a resin protective layer with enhanced thermal conductivity for efficient heat dissipation and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin insulating layer is formed by filling resin to cover the columnar conductors, then the insulating layer provides electrical insulation and structural support, but gaps may form at the boundaries between the resin and conductor ends due to thermal contraction during curing
Solution Approach 1:
The patent applies preliminary action by forming a protruding portion on the resin insulating layer at the boundary region before final curing completes. This protruding portion anticipates the thermal contraction that will occur during curing and pre-compensates for it, ensuring that the resin maintains close contact with the conductor ends even after contraction, thereby preventing gap formation and moisture ingress
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal contraction characteristics of the resin during curing. By adjusting curing temperature, pressure, and resin composition, the patent optimizes the contraction behavior to minimize gap formation while still achieving complete curing. The protruding portion geometry is also optimized to account for expected contraction parameters
2Stability of the object's composition
If the resin insulating layer undergoes thermal contraction during curing, then the resin achieves complete curing and structural stability, but positional deviation and tilting of columnar conductors may occur
Solution Approach 1:
The patent applies beforehand cushioning by creating a protruding portion that extends beyond the conductor end at the boundary region. This protruding portion acts as a cushion or buffer zone that absorbs the dimensional changes during thermal contraction, preventing the conductors from shifting or tilting while still allowing the resin to cure completely. The protruding portion provides mechanical support that maintains conductor positioning throughout the curing process
3Reliability
If the boundary regions around conductor ends are left uncovered, then the resin insulating layer maintains uniform thickness, but moisture can enter through gaps and degrade inductor characteristics
Solution Approach 1:
The patent applies local quality by creating a protruding portion specifically at the boundary regions where conductors meet the resin surface, while leaving the rest of the resin insulating layer with uniform thickness. This localized modification provides enhanced moisture protection exactly where gaps are most likely to form, without unnecessarily complicating the overall resin structure or affecting other regions that already have adequate coverage
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 solution effectively prevents gap formation and positional deviations, enhancing the reliability and accuracy of the inductor component by ensuring close contact between the resin and metal pins, while also improving heat dissipation and inductance.
Implementation Method 1
because the filled resin is contracted when it is thermally cured, gaps may be caused in some cases at boundaries between the resin insulating layer and the respective ends of the columnar conductors
Implementation Method 2
includes a resin protective layer with enhanced thermal conductivity for efficient heat dissipation
Data Source
AI summary
A first resin layer (resin insulating layer) is formed by forming first and third covering portions in close contact with peripheral surfaces of respective end portions of first and second metal pins on the side closer to first end surfaces thereof, and by forming a body portion in a state of covering the respective surfaces of the first and third covering portions. Therefore, even when the first resin layer is thermally contracted, boundary regions of the one principal surface of the first resin layer around the respective end portions of the first and second metal pins on the side closer to the first end surfaces are filled with the first and third covering portions. Hence gaps can be prevented from being generated in those boundary regions, and a columnar conductor (first metal pin) can be avoided from deviating in position.