Inductor Core Resin Permeation for Thermal Stability
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Solution Overview
Problem
There is a need for electronic components, such as inductors, that offer improved electrical characteristics and reliability while enabling high-density mounting and low-height mounting on circuit boards, while also improving productivity and reducing costs.
Innovation Solution
The development of an electronic component featuring a base material of soft magnetic alloy grains with a permeated resin outer sheath, where the resin material penetrates into the base material to a specific depth, and contains a filler by 50% or more, enhancing the component's durability and mounting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the outer dimensions (especially height dimension) of the inductor are reduced to enable high-density mounting and low-height mounting, then the mountability is improved, but the electrical characteristics and reliability may deteriorate
Solution Approach 1:
The patent uses a composite resin material containing ferrite powder and epoxy resin as the outer sheath material. This composite structure allows the resin to penetrate into the porous ferrite core, creating a bonded interface that reduces linear expansion coefficient differences and improves reliability while maintaining small dimensions
Solution Approach 2:
The ferrite core is designed with a porous structure (porosity: 30-70%) that allows the resin material to penetrate deeply into the core. This penetration creates strong bonding between the core and outer sheath, improving mechanical strength and thermal stability while enabling compact sizing
2Reliability
If the composition of the outer sheath resin material is adjusted to match the linear expansion coefficient of the ferrite core, then the durability against temperature changes is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the physical state and composition parameters of the resin material by controlling the curing process. The resin is applied in a uncured state to allow penetration, then cured to form a bonded structure. This parameter control achieves linear expansion coefficient matching without complex material formulation
Solution Approach 2:
The porous ferrite core structure automatically facilitates resin penetration through capillary action during the curing process. The core's own porous structure serves the function of resin absorption and distribution, eliminating the need for additional penetration mechanisms or complex processing steps
3Strength
If a ferrite core with porous structure is used to enable resin penetration, then the bonding strength and thermal stability are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a porosity range (30-70%) rather than a precise single value, allowing manufacturing flexibility. The resin formulation and curing conditions are also optimized to work effectively across this porosity range, reducing the impact of manufacturing variations
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 results in electronic components with improved electrical characteristics, enhanced reliability, and increased productivity, allowing for smaller size and higher functionality while maintaining resistance to environmental changes, such as temperature variations.
Implementation Method 1
the resin material is permeated into the base material from the interface of the base material in contact with the outer sheath resin part
Data Source
AI summary
An electronic component has a drum-shaped core member constituted by an assembly of soft magnetic alloy grains containing iron (Fe), silicate (Si) and chromium (Cr), a coil conductive wire wound around the core member, a pair of terminal electrodes connected to ends of the coil conductive wire, and an outer sheath resin part covering the wound coil conductive wire and constituted by a magnetic powder-containing resin; wherein there is an area where only the resin material in the magnetic powder-containing resin is permeated from the surface of the core member to a specified depth.