Inductor Vertical Wire Protection Film to Suppress Leak Paths
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Solution Overview
Problem
Conventional inductor components face issues with the formation of leak paths between vertical wires due to excessive entry of metal magnetic powder into the side surfaces of the vertical wires, increasing the contact area and conductivity.
Innovation Solution
The inductor component incorporates a conductive protection film with higher hardness than the vertical wires, covering at least a part of the side surfaces of the vertical wires, reducing the entry of magnetic powder and minimizing contact areas, thereby suppressing the formation of leak paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the vertical wire is covered with the metal magnetic powder-containing resin, then the inductor component structure is formed, but the metal magnetic powder excessively enters the side surface of the vertical wire, increasing contact area and forming leak paths
Solution Approach 1:
An insulating film is introduced as an intermediary layer between the vertical wire and the metal magnetic powder-containing resin. This insulating film prevents direct contact and excessive entry of metal magnetic powder into the vertical wire side surface, thereby eliminating leak paths while still allowing the resin to provide structural support and magnetic properties.
Solution Approach 2:
A thin insulating film is applied to cover the side surface of the vertical wire. This thin film acts as a protective barrier that prevents metal magnetic powder from excessively entering the vertical wire structure, maintaining electrical isolation and preventing leak path formation between adjacent vertical wires.
2Area of stationary object
If the contact area between metal magnetic powder and vertical wire is increased, then the resin coverage is improved, but a leak path is formed between the vertical wires
Solution Approach 1:
The insulating film serves as a mediator that controls the contact area between metal magnetic powder and the vertical wire. It allows for regulated interaction while maintaining electrical isolation, preventing the formation of leak paths even when metal magnetic powder is in close proximity to the vertical wire surface.
3Device complexity
If no protective film is provided on the vertical wire, then the manufacturing process is simpler, but metal magnetic powder enters the vertical wire side surface excessively
Solution Approach 1:
A thin insulating film is applied to the vertical wire side surface to prevent excessive entry of metal magnetic powder. This thin film provides effective protection while minimizing the increase in device complexity, as it can be applied through standard thin-film deposition techniques integrated into the existing manufacturing process.
Solution Approach 2:
The introduction of an insulating film changes the surface properties and electrical parameters of the vertical wire, creating a barrier that controls metal magnetic powder entry. This parameter change enables precise control over the interaction between the resin and vertical wire without significantly complicating the manufacturing process.
Data Source
AI summary
An inductor component is capable of suppressing formation of a leak path between vertical wires. Such an inductor component includes an element body that includes a plurality of magnetic powders, at least one of which contains an Fe element as a main component, and has a first principal surface and a second principal surface; an inductor wire that is provided in the element body and extends along a plane parallel to the first principal surface; a vertical wire that is provided in the element body, is connected to an end of the inductor wire, and extends to the first principal surface in a direction orthogonal to the first principal surface; and a conductive protection film that covers at least a part of a side surface of the vertical wire extending along a direction orthogonal to the first principal surface and has a higher hardness than the vertical wire.