Multilayer Coil Structure With Resin-Extended Electrode Bonding
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Solution Overview
Problem
Existing multilayer coil components face issues with adhesion strength between the element body and external electrodes due to voids formed by metal particle accumulation, which can lead to peeling and reduced reliability.
Innovation Solution
A multilayer coil component design where the space between metal magnetic particles is filled with a first resin, and the external electrode includes a resin electrode with a conductor powder dispersed in a second resin that extends into the element body, enhancing adhesion strength by bonding with the first resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal particles are accumulated to form the element body, then the magnetic properties are improved, but voids are generated reducing adhesion strength
Solution Approach 1:
The patent introduces a resin material as an intermediary substance that penetrates into the voids between metal particles in the element body and extends to the external electrode. This resin mediator creates a bridging connection that enhances adhesion strength and prevents peeling, resolving the contradiction between maintaining magnetic particle accumulation and achieving reliable electrode bonding.
Solution Approach 2:
The patent utilizes the porous structure created by voids between metal particles not as a defect but as a beneficial feature. The resin material is designed to penetrate and fill these pores, creating a interlocking structure that enhances adhesion. The porous allowance between metal particles is intentionally utilized to accommodate the resin extension, transforming the harmful voids into advantageous bonding channels.
2Strength
If resin material is used to fill voids, then adhesion is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the void-filling function and the electrode-bonding function into a single integrated resin material system. The same resin that fills the voids between metal particles also extends to bond the external electrode, eliminating the need for separate adhesive layers or complex multi-step bonding processes. This consolidation improves adhesion while maintaining manufacturing simplicity.
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 extended second resin improves the adhesion between the element body and the resin electrode, reducing peeling and enhancing the reliability of the multilayer coil component.
Implementation Method 1
the second resin connected from the resin electrode extends into the element body... the adhesion strength between the element body and the resin electrode can be enhanced... the first resin and the second resin may be bonded to each other in the element body
Data Source
AI summary
A multilayer coil component includes: an element body containing a plurality of metal magnetic particles; a coil disposed in the element body; and an external electrode disposed on a surface of the element body and electrically connected to the coil. At least a part of a void part between the metal magnetic particles in the element body is filled with a first resin, the external electrode has a resin electrode containing a second resin and a conductor powder dispersed in the second resin, and the second resin connected from the resin electrode extends into the element body.