Surface Mount Coil With Thermoplastic Resin Layer
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Solution Overview
Problem
Surface mount coil components with increased magnetic material particle volume suffer from fragility and surface unevenness, leading to poor handling properties during mounting on printed circuit boards.
Innovation Solution
A surface mount coil component design featuring a thermoplastic resin layer on the mounting surface with an interlayer connection conductor, which is heated to bond with the coil's end portion, improving handling and preventing terminal peeling or defects, while maintaining magnetic saturation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the volume of magnetic material particles in the element body is increased to improve saturation magnetic flux density and performance, then the performance of the element body is improved, but the surface of the element body becomes fragile and magnetic material particles fall off, and unevenness is generated on the surface
Solution Approach 1:
The patent applies composite materials by combining magnetic material particles with a binder resin to form an element body. This composite structure allows the magnetic particles to provide high saturation magnetic flux density while the binder resin provides structural integrity and surface strength, preventing particle fallout and surface unevenness.
Solution Approach 2:
The patent optimizes the volume ratio of magnetic material particles to binder resin, and adjusts molding parameters such as pressure and temperature, to achieve a balance between magnetic performance and surface integrity. By controlling these parameters, the element body maintains both high saturation magnetic flux density and sufficient surface strength.
2Reliability
If the volume of magnetic material particles in the element body is increased to improve saturation magnetic flux density, then the performance is improved, but the handling property of the coil component deteriorates due to surface fragility and particle fallout
Solution Approach 1:
The binder resin in the composite element body acts as a binding agent that holds magnetic particles together, creating a robust surface that resists particle fallout during handling and mounting operations, thereby improving handling properties while maintaining magnetic performance.
Solution Approach 2:
By optimizing the molding pressure and temperature parameters, the patent enhances the bonding between magnetic particles and binder resin, creating a more durable surface that withstands handling stresses without particle fallout or surface degradation.
3Strength
If a thermoplastic resin layer is provided on the mounting surface and heated for bonding, then the handling property and bonding strength are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent utilizes the phase transition of the thermoplastic resin layer from solid to molten state during heating, and then back to solid state upon cooling. This phase transition enables strong bonding between the resin layer and the coil component surface, while the process can be integrated into existing manufacturing equipment, minimizing additional 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
Enhances the handling and bonding strength of the surface mount coil components, ensuring reliable electrical connection and improved direct-current superposition characteristics.
Implementation Method 1
softening the thermoplastic resin layer by heating and then bonding the thermoplastic resin layer to the element body
Implementation Method 2
bonding the thermoplastic resin layer to the element body
Data Source
AI summary
A surface mount coil component includes an element body defining a compact including magnetic material particles; a coil that is buried, excluding an end portion of the coil, in the element body; and an input-output terminal electrically connected to the end portion of the coil. A thermoplastic resin layer is provided on a surface on a mounting surface side of the element body. An interlayer connection conductor is provided in the thermoplastic resin layer. The input-output terminal is provided on a surface of the thermoplastic resin layer and is electrically connected to the end portion of the coil via the interlayer connection conductor.