Power Inductor Coupling Layer and Alloy Electrode
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Solution Overview
Problem
Power inductors with metal bodies face challenges in achieving high current characteristics due to increased material loss from eddy current and hysteresis at high frequencies, and the external electrodes formed using metal paste have weak coupling forces, leading to separation issues under tensile stress.
Innovation Solution
A power inductor design featuring a body with a coil pattern, an external electrode extending to adjacent surfaces, and a coupling layer between the body and the external electrode, where the external electrode is formed using the same material and method as the coil pattern, and a surface insulation layer is used to enhance insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the body is made of metal powder to increase saturation magnetization value, then high current characteristics are improved, but material loss increases due to eddy current and hysteresis at high frequency
Solution Approach 1:
The patent applies different materials to different parts of the inductor: metal powder is used in the body for high saturation magnetization and current handling, while the external electrode uses a copper-nickel-tin alloy composition optimized for low loss at high frequencies. This local differentiation allows each component to perform optimally for its specific function without compromising the other.
Solution Approach 2:
The external electrode is constructed as a composite material system with a copper base (5-30 wt%) providing high conductivity, nickel (20-40 wt%) providing magnetic properties and corrosion resistance, and tin (30-60 wt%) providing solderability and low loss characteristics. This composite structure resolves the contradiction between high current capability and low loss by combining materials with complementary properties.
2Ease of manufacture
If the external electrode is formed by applying metal paste, then the electrode can be connected to the coil pattern, but the coupling force between the body and external electrode is weak causing separation under tensile force
Solution Approach 1:
The patent changes the material parameters of the external electrode from conventional metal paste to a specific copper-nickel-tin alloy composition with controlled proportions. This parameter change fundamentally improves the coupling force and tensile strength while maintaining ease of manufacture through established paste application processes.
Solution Approach 2:
The external electrode material is formulated as a homogeneous alloy mixture of copper, nickel, and tin particles in specific ratios, ensuring uniform distribution and consistent coupling properties throughout the electrode structure. This homogeneity prevents weak spots that would cause separation under stress.
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 improved coupling force and tensile strength between the body and external electrode prevent separation, while the increased insulation properties and uniform parylene coating enhance the inductor's performance and capacity.
Implementation Method 1
a coupling layer provided between the body and an extended area of the external electrode
Implementation Method 2
a surface insulation layer disposed on at least one area of a surface of the body
Data Source
AI summary
Disclosed are a power inductor and a method of manufacturing the same. The power inductor includes a body, a coil pattern provided in the body, an external electrode disposed on at least one surface of the body and extending to at least the other surface of the body, which is adjacent thereto, and a coupling layer provided between the body and an extended area of the external electrode.