Resin-Impregnated Multilayer Inductor for Void-Related Strength Loss
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Solution Overview
Problem
The presence of voids between metallic magnetic particles in multilayer electronic components reduces the strength of the multilayer body, affecting the performance of power inductors in DC-DC converters.
Innovation Solution
A multilayer inductor design that includes an element body with magnetic layers containing iron powder, a coil conductor wound inside the magnetic body, and an outer electrode connected to the coil conductor. The design involves impregnating a resin into the voids within the magnetic body and into the pores of the coil conductor, particularly in the vicinity of the magnetic layers, to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic magnetic layers are used to form the magnetic body, then magnetic properties are improved, but voids are generated between particles causing decreasing element body strength
Solution Approach 1:
A resin layer is introduced as an intermediary substance to fill the voids between metallic magnetic particles in the magnetic body. This resin acts as a mediator that bonds the particles together, eliminating the harmful voids while preserving the magnetic properties of the metallic particles. The resin layer specifically fills gaps in the magnetic body without interfering with the coil conductor's electrical function.
Solution Approach 2:
The magnetic body is transformed from a homogeneous metallic particle structure into a composite material system consisting of metallic magnetic particles embedded in a resin matrix. This composite structure combines the magnetic properties of the metallic particles with the binding and void-filling properties of the resin, achieving both magnetic performance and structural strength.
2Power
If coil conductor is wound inside magnetic body, then inductance function is achieved, but pores are generated in coil conductor reducing overall strength
Solution Approach 1:
The resin impregnation process merges the treatment of voids in the magnetic body with pores in the coil conductor into a single operation. The resin simultaneously fills both types of voids during one impregnation step, creating a unified structural reinforcement that strengthens both the magnetic body and the coil conductor without requiring separate processing steps.
3Strength
If resin is provided in voids and pores, then element body strength is increased, but manufacturing process complexity increases
Solution Approach 1:
The resin impregnation is performed as a preliminary action before final assembly and testing. By filling voids and pores with resin early in the manufacturing process, subsequent handling and assembly operations benefit from the pre-strengthened structure, reducing the risk of damage during assembly and eliminating the need for additional strengthening steps later.
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 resin impregnation effectively reduces voids and pores, thereby increasing the element body strength of the multilayer inductor, improving its performance and reliability in high-current applications.
Implementation Method 1
A resin is provided in voids inside the magnetic body, and pores exist in the coil conductor at least in a vicinity of a magnetic layer, and the resin is provided in at least a part of the pores
Data Source
AI summary
A multilayer inductor includes an element body that constitutes a magnetic body by stacking magnetic layers containing iron powder and that has a coil obtained by winding a coil conductor inside the magnetic body, and an outer electrode that is electrically connected to the coil conductor. A resin is provided in voids inside the magnetic body, and the resin is provided in at least a part of pores in the coil conductor at least in a vicinity of a magnetic layer.