Passive electrical component with coating to improve the loading capacity

Patent metadata

Field	Value
Publication number	US-11646148-B2
Application number	US-201716322838-A
Country	US
Kind code	B2
Filing date	Aug 4, 2017
Priority date	Aug 4, 2016
Publication date	May 9, 2023
Grant date	May 9, 2023

Abstract

The invention relates to a passive electrical component, especially a coil, having an interlayer, wherein the interlayer has a lower coefficient of thermal expansion than the surface of the passive electrical component covered with the interlayer, and disposed atop that a plasma-polymeric carbon-containing coating having a carbon content measured at a depth of 80 nm away from the side of the plasma-polymeric coating remote from the interlayer, wherein the plasma-polymeric coating comprises a carbon content of 50 to 100 atom %, preferably 50 to 90 atom %, or is configured as an organometallic coating a carbon content of 2 to 50 atom %, in each case measured by means of XPS.

First claim

What is claimed is:

1. A passive electrical component comprising:
an interlayer covering a surface of the passive electrical component;
wherein the interlayer has a coefficient of thermal expansion which is lower than a coefficient of thermal expansion of the surface of the electrical component covered by the interlayer; and
a plasma-polymeric coating disposed on top of the interlayer and having a carbon content measured at a depth of 80 nm away from a side of the plasma-polymeric coating remote from the interlayer;
wherein the plasma-polymeric coating comprises at least one of the carbon content being in a range of 50 to 100 atom % and an organometallic coating having a carbon content being in a range of 2 to 50 atom %,
wherein the carbon content is measured by means of XPS and based on atoms detected by XPS.

2. The passive electrical component according to claim 1 , wherein the interlayer comprises a ceramic layer.

3. The passive electrical component according to claim 1 , wherein the interlayer comprises at least one of a crosslinked oil, an uncrosslinked oil, a crosslinked silicone oil, an uncrosslinked silicone oil, a zone of crosslinked oil present between the interlayer and the plasma-polymeric coating, and a zone of crosslinked silicone oil present between the interlayer and the plasma-polymeric coating.

4. The passive electrical component according to claim 1 , wherein the plasma-polymeric coating comprises silicon.

5. The passive electrical component according to claim 1 , wherein the surface of the passive electrical component covered by the interlayer comprises a material selected from the group consisting of a copper, an aluminum, an alloy comprising a copper, an alloy comprising an aluminum, and an alloy comprising a copper and an aluminum.

6. The passive electrical component according to claim 1 , wherein the plasma-polymeric coating has at least one of:
an extension before cracking of ≥2.5%, and
a hardness measured by means of nanoindentation in the range from 2 to 6 GPa.

7. The passive electrical component according to claim 1 ,
wherein the plasma-polymeric coating comprises a proportion, determinable by measurement by means of XPS measured at a depth of 80 nm away from the side of the plasma-polymeric coating remote from the interlayer, of at least one of
5 to 40 atom % of silicon, and
30 to 70 atom % of oxygen; and
wherein the proportion is based on a total number of carbon, silicon and oxygen atoms present in the plasma-polymeric coating.

8. The passive electrical component according to claim 1 , wherein the plasma-polymeric coating has a thickness in a range of 100 nm to 100 μm.

9. The passive electrical component according to claim 1 , wherein the interlayer and the plasma-polymeric layer together have a breakdown resistance measured according to DIN EN 60243-1 and DIN EN 60243-2 testing methods of ≥100 V measured up to a maximum current flow of 3 mA.

10. The passive electrical component according to claim 1 , wherein the passive electrical component after aging at 300° C. for 500 hours in an air circulation oven under dry circulating air followed by cooling to 20° C. within one hour has a post-aging and cooling resistance of at least 80% of a breakdown resistance prior to aging.

11. The passive electrical component according to claim 1 , wherein the passive electrical component does not have a visually detectable etch attack in a region of the plasma-polymeric layer after the region is exposed to a 1 mol/L NaOH solution for a duration of 20 minutes at room temperature.

12. A process for producing the passive electrical component according to claim 1 , comprising the steps of:
a) providing a substrate of the passive electrical component;
b) disposing the interlayer on the substrate thereby covering the surface of the passive electrical component; and
c) depositing the plasma-polymeric coating on top of the interlayer.

13. The process according to claim 12 , wherein step c) is conducted in a high-frequency plasma polymerization reactor under low pressure and the substrate is connected as the cathode.

14. The process according to claim 12 , wherein step c) is conducted via a wet chemical process.

15. The passive electrical component according to claim 2 , wherein the ceramic layer is selected from the group of ceramic layers consisting of TiO 2 , SiO 2 , Al 2 O 3 , Ti x N y or BN.

16. The passive electrical component according to claim 2 , wherein the ceramic layer further comprises an eloxal layer.

17. The passive electrical component according to claim 6 , wherein the hardness is in a range of 2.4 to 5 GPa.

18. The passive electrical component according to claim 7 , wherein the plasma-polymeric coating comprises the proportion of at least one of:
20 to 32 atom % of silicon, and
40 to 64 atom % of oxygen.

19. The passive electrical component according to claim 1 , wherein the plasma-polymeric coating has a thickness in a range of 200 nm to 50 μm.

20. The passive electrical component according to claim 1 , wherein the plasma-polymeric coating has a thickness in a range of 500 nm to 10 μm.

Assignees

• Fraunhofer Ges Forschung
• Fraunhofer Ges Zur Foerderung Dee Angewandten Forschung E V

Inventors

• Salz Dirk
• Wilken Ralph
• Dieckhoff Stefan
• Burchardt Malte
• Dölle Christopher
• Regula Christoph
• Wöstmann Franz-Josef

Classifications

• H01F41/12

  Insulating of windings ({impregnating or encapsulating of transformers H01F41/005} ; of conductors in general H01B13/06) · CPC title

• B05D2202/45

  based on Cu · CPC title

• B05D2202/25

  based on Al · CPC title

• B05D1/62 Primary

  Plasma-deposition of organic layers (plasma deposition in general C23C14/00, C23C16/00) · CPC title

• H01F5/06 Primary

  Insulation of windings · CPC title