Chamfered Terminal Electrode for Coil Component Wire Protection
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Solution Overview
Problem
In coil components, stress from thermal expansion and shrinkage, as well as manufacturing processes, can damage the insulating coating layer and disconnect the central conductor when the wire is in contact with the terminal electrode, particularly due to the formation of sharp 'droops' or 'burs' on the edge of the metallic terminal electrode.
Innovation Solution
A chamfered edge portion on the terminal electrode is used to distribute the load applied to the wire, ensuring multiple points of contact and reducing the likelihood of damage to the insulating coating layer and disconnection of the central conductor, while maintaining a thickness of 0.15 mm or less for the terminal electrode and a diameter of 35 μm or less for the central conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal electrode is made with a thin metallic plate (0.15 mm or less) to reduce size and weight, then the compactness is improved, but sharp droops or burrs are likely to form on the edge portion during press working, which damages the wire insulation and causes conductor disconnection
Solution Approach 1:
The edge portion of the terminal electrode is chamfered in advance before the wire is installed. This preliminary action removes sharp droops and burrs that would otherwise form during press working of thin metallic plates, preventing damage to the wire insulation and conductor disconnection while maintaining the compact thin-profile design
Solution Approach 2:
The edge portion geometry is changed from a sharp edge (prone to droops and burrs) to a chamfered edge with specific angular parameters. This parameter change in the edge geometry distributes contact stress and eliminates the harmful sharp features that cause wire damage, allowing thin plate usage without compromising reliability
2Productivity
If press working is performed on the metallic plate to manufacture the terminal electrode, then the manufacturing efficiency is improved, but droops or burrs are formed on the edge portion, making wire damage and conductor disconnection more likely
Solution Approach 1:
The chamfering of the edge portion is performed as a preliminary action during or after the press working process, before the wire is installed. This eliminates the need for additional deburring operations and ensures that the harmful droops and burrs are removed while maintaining the efficiency of the press working manufacturing process
Solution Approach 2:
The chamfering process, which is sometimes necessary to remove defects from press working, is applied systematically to all edge portions. This converts the potentially harmful droops and burrs into a beneficial feature where the chamfered geometry distributes stress and prevents wire damage, turning a manufacturing challenge into a reliability enhancement
Data Source
AI summary
A coil component comprises a wire and a terminal electrode. The wire includes a linear central conductor and an insulating coating layer that covers a circumferential surface of the central conductor. The terminal electrode is electrically connected to the central conductor at an end portion of the wire, and includes a metallic plate. The terminal electrode also includes an edge portion in contact with the wire. The edge portion is chamfered.