Multilayer Coil Structure With Close Contact Layer Against Peeling
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Solution Overview
Problem
The adhesion strength between laminated insulation layers in multilayer coil components decreases due to residue from the manufacturing process, leading to interfacial peeling under thermal loads, which can cause insulation resistance degradation and operational failures.
Innovation Solution
A multilayer coil component design incorporating a close contact layer made of metal with desired adhesion to the resin insulation layers, positioned between the insulation layers and not connected to the coil conductor layer, to enhance adhesion strength and prevent peeling, along with a manufacturing method that forms this close contact layer using seed layers and etching processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin insulation layers are laminated in a multilayer coil component, then insulation properties are improved, but adhesion strength between layers decreases due to manufacturing residues
Solution Approach 1:
A close contact layer made of metal (such as copper or aluminum) is introduced as an intermediary between the resin insulation layers. This close contact layer serves dual purposes: it provides excellent adhesion to the resin layers while also serving as a conductor path. The metal layer effectively bonds to the resin layers, preventing interfacial peeling and maintaining adhesion strength despite the presence of manufacturing residues like resist material.
2Productivity
If thermal load is applied during manufacturing or mounting, then electrical functionality is achieved, but interfacial peeling occurs due to reduced adhesion strength
Solution Approach 1:
The patent employs a composite structure combining metal (close contact layer) and resin (insulation layers). The metal layer provides thermal stability and strong adhesion to the resin layers, creating a composite material system that can withstand thermal loads during manufacturing and mounting processes. This composite approach prevents interfacial peeling by leveraging the superior thermal and adhesive properties of the metal layer.
3Ease of operation
If moisture enters from the exterior, then operational functionality is maintained, but insulation resistance deteriorates due to short circuit or open circuit
Solution Approach 1:
The close contact layer acts as an intermediary barrier that prevents moisture penetration between resin insulation layers. By providing a continuous metal layer with excellent adhesion, it blocks moisture pathways that would otherwise cause insulation resistance deterioration. This intermediary layer maintains operational functionality while protecting against moisture-induced failures such as short circuits or open circuits.
Data Source
AI summary
A coil component includes a multilayer body in which a plurality of resin insulation layers is laminated, a spiral-shaped coil conductor layer disposed on main surface of one of the resin insulation layers, and a close contact layer disposed at interfaces between two of the resin insulation layers and not connected to the coil conductor layer. The close contact layer contains a metal having desired adhesion to the resin insulation layers.