Multilayer Coil Component Side Gap Permeation
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Solution Overview
Problem
Multilayer coil components face issues with internal stress and decreased direct current resistance due to differences in thermal expansion and sintering shrinkage between magnetic ceramic and internal conductor layers, leading to potential conductor fracture and reliability concerns, especially in compact designs.
Innovation Solution
A multilayer coil component design with a ceramic laminate structure where internal conductors are interlayer-connected to form a spiral coil without voids at interfaces with magnetic ceramic, utilizing a NiCuZn ferrite ceramic with zinc borosilicate-based low softening point glass and SnO2, and a method to permeate an acidic solution through side gaps to reduce stress and prevent conductor fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If internal conductor layers are thinned to enable plating solution permeation, then stress relief is achieved, but direct current resistance decreases and conductor fracture liability increases
Solution Approach 1:
The patent applies local quality by thinning the internal conductor layers only at specific locations where plating solution permeation is needed, rather than uniformly thinning the entire conductor layers. This localized thinning creates channels for stress relief while preserving the thickness and strength of the conductor layers in other critical areas, thereby maintaining direct current resistance and preventing conductor fracture. The thinning is strategically applied only where necessary for stress management.
2Volume of moving object
If magnetic ceramic layer thickness is decreased for compact product design, then product size is reduced, but internal stress concentration increases and conductor fracture risk increases
Solution Approach 1:
The patent applies local quality by introducing voids at specific interfaces between magnetic ceramic layers and internal conductor layers, rather than uniformly reducing the thickness of all magnetic ceramic layers. This localized structural modification allows for stress relief at critical interfaces while maintaining sufficient overall thickness of the magnetic ceramic layers to provide mechanical support and prevent stress concentration that would lead to conductor fracture. The compact size is achieved through optimized layer arrangement rather than uniform thinning.
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 solution reduces internal stress, maintains high direct current resistance, and enhances the reliability of multilayer coil components by preventing conductor fracture and ensuring stable magnetic permeability and strength, even in compact designs.
Implementation Method 1
allowing an acidic solution to permeate the magnetic ceramic element from a side surface thereof through a side gap portion which is a region between side portions of the internal conductors and the side surface of the magnetic ceramic element
Implementation Method 2
an internal stress generated by the difference in coefficient of thermal expansion between magnetic ceramic layers and internal conductor layers
Implementation Method 3
a magnetic ceramic element formed by firing a ceramic laminate which is formed by laminating magnetic ceramic layers to each other
Data Source
AI summary
A highly reliable multilayer coil component is provided without forming voids between magnetic ceramic layers and internal conductor layers. According to the multilayer coil component, an internal stress problem is reduced, the direct current resistance is low, and fracture of internal conductors caused by the surge or the like is not likely to occur. An acidic solution is allowed to permeate a magnetic ceramic element from a side surface thereof through a side gap portion which is a region between side portions of the internal conductors and the side surface of the magnetic ceramic element and to reach interfaces between the internal conductors and a magnetic ceramic located therearound. A pore area ratio of the magnetic ceramic of the side gap portion which is located between the side portions of the internal conductors and the side surface of the magnetic ceramic element is set in the range of 6% to 28%.