Inductor Sealing Resin Particle Distribution for DC Superimposition
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Solution Overview
Problem
Inductors with reduced size suffer from deteriorated DC superimposition characteristics and are prone to sealing irregularities due to poor fluidity of magnetic mold resin during the pressure-molding process.
Innovation Solution
The use of a soft magnetic alloy powder-containing resin with a specific particle size distribution, featuring two peaks where the second peak is half the size of the first peak, and a magnitude ratio between 0.2 and 0.6, improves wettability and fluidity, ensuring smooth sealing without voids and maintaining excellent DC superimposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inductor size is reduced to increase component mounting density, then the volume of the inductor core is reduced, but the DC superimposition characteristics deteriorate
Solution Approach 1:
The invention changes the particle size distribution parameters of the soft magnetic alloy powder in the sealing resin. By controlling the particle size distribution to have two peaks with specific characteristics (second peak particle size is one-half of the first peak, and magnitude ratio is 0.2-0.6), the resin achieves optimal fluidity to fill small gaps completely, maintaining DC superimposition characteristics even in reduced-size inductors
Solution Approach 2:
The invention uses a composite sealing resin material containing soft magnetic alloy powder with specific particle size distribution. This composite material combines the magnetic properties needed for DC superimposition characteristics with the fluidity required to fill gaps in compact inductor structures, achieving both size reduction and performance maintenance
2Reliability
If pressure-molding is used to seal the coil with magnetic mold resin, then the coil is sealed, but sealing irregularities such as voids between loops occur due to poor fluidity
Solution Approach 1:
The invention changes the particle size distribution parameters of the soft magnetic alloy powder to achieve optimal resin fluidity. The two-peak distribution with specific characteristics allows the resin to flow smoothly and fill all gaps uniformly during molding, eliminating voids and sealing irregularities while maintaining complete coil 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 approach enhances DC superimposition characteristics while preventing sealing irregularities, ensuring reliable performance in high-density mounting applications by improving the fluidity and wettability of the sealing material, thus effectively sealing the inductor without mechanical issues associated with pressure-molding.
Implementation Method 1
the soft magnetic alloy powder-containing resin contains two groups of large and small particles having a first peak and second peak in their particle size distribution, where the particle size corresponding to the second peak is one-half the particle size corresponding to the first peak, and a magnitude ratio (abundance ratio) of the second peak and first peak is 0.2 or more but 0.6 or less
Implementation Method 2
improves wettability and fluidity, ensuring smooth sealing without voids
Data Source
AI summary
An inductor includes soft magnetic alloy powder-containing resin that contains amorphous soft magnetic alloy powder, which resin is used as a sealing material that seals a coil wound around a winding core of the core. This soft magnetic alloy powder-containing resin contains two groups of large and small particles having a first peak and second peak in their particle size distribution, where the particle size corresponding to the second peak is equal to or smaller than one-half the particle size corresponding to the first peak, and the magnitude ratio (abundance ratio) of the second peak and first peak is 0.2 or more but 0.6 or less. The inductor demonstrates improved DC superimposition characteristics and does not cause sealing irregularities.