Multilayer Coil Structure Using Pore-Forming Conductor Layers
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Solution Overview
Problem
The production of multilayer coil components faces internal stress issues due to differing shrinkage ratios between magnetic body layers and coil conductor layers during firing, which existing methods fail to adequately alleviate, especially at the interface between the layers.
Innovation Solution
A method involving the formation of a multilayer compact with conductive and insulating paste layers, where the conductive paste has a PVC of 60% to 80% and includes generating pores within the coil conductor layers during firing to reduce internal stress, and the use of insulator portions with specific pore area ratios to alleviate stress and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive paste has a PVC of 60% to 80% to generate pores during firing, then internal stress is suppressed, but the manufacturing precision of the coil conductor layer may be affected
Solution Approach 1:
The patent applies parameter changes by optimizing the PVC of the conductive paste to a specific range (60% or more and 80% or less). This parameter control ensures that sufficient pores are generated during firing to alleviate internal stress, while maintaining the coil conductor layer's electrical conductivity and structural integrity within acceptable manufacturing precision limits.
2Reliability
If pores are generated within the coil conductor layers during firing, then the structural integrity is improved, but the complexity of the firing process increases
Solution Approach 1:
The patent applies self-service by utilizing the conductive paste's own properties (PVC of 60% or more and 80% or less) to generate pores during the standard firing process. The paste composition itself enables pore formation without requiring additional process steps, equipment, or complex process control, thereby improving structural integrity while avoiding increased process complexity.
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
The method effectively suppresses internal stress and reduces defects such as cracking in the multilayer coil components by creating pores within the coil conductor layers during firing, resulting in a highly reliable product with improved structural integrity.
Implementation Method 1
generating pores within the coil conductor layers during firing to reduce internal stress
Implementation Method 2
the magnetic body layers and the coil conductor layers exhibit different shrinkage ratios during firing, and internal stress can occur due to the difference in the shrinkage ratio
Data Source
AI summary
A highly reliable multilayer coil component in which the internal stress is further alleviated, and a method for producing the same. The method produces a multilayer coil component that includes an insulator portion, a coil that is embedded in the insulator portion and includes a plurality of coil conductor layers electrically connected to one another, and an outer electrode that is disposed on a surface of the insulator portion and is electrically connected to an extended portion of the coil. The method includes forming a conductive paste layer by using a conductive paste; forming an insulating paste layer by using an insulating paste; forming a multilayer compact that includes the conductive paste layer and the insulating paste layer; and firing the multilayer compact, in which the conductive paste has a PVC of 60% or more and 80% or less (i.e., from 60% to 80%).