Coil Base Plate Passage for Protecting Lead Wire Insulation

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Solution Overview

Problem

Existing coil devices face issues with insulation failure and breakage of the leading portion of the wire due to contact with the outer peripheral edge of the base plate, leading to reduced reliability.

Innovation Solution

A coil device design that incorporates a core with a winding core portion, a winding portion of a wire in a coil shape around the core, and a base plate with a terminal. The base plate features a base-side passage, such as a notched dent or through hole, to guide the leading portion of the wire from the winding portion to the wire connection portion, minimizing contact with the base plate edge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the wire leading portion is connected on the outside of the side surface of the base plate, then the wire can be easily connected to the terminal, but the insulating coating of the wire may be damaged due to contact with the outer peripheral edge of the base plate

Engineering Contradiction:

Improveease of wire connectionVSAvoidinsulation reliability of wire

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A groove is formed on the side surface of the base plate to serve as an intermediary pathway for the wire leading portion. This groove guides the wire from the winding portion to the terminal connection point while preventing direct contact with the outer peripheral edge of the base plate, thus protecting the insulating coating without complicating the connection process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The groove creates a third-dimensional pathway on the side surface of the base plate, allowing the wire to traverse through a protected channel rather than being exposed on the surface. This dimensional approach separates the wire path from the harmful outer edge while maintaining easy connection capability

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If the wire leading portion passes close to the outer peripheral edge of the base plate for connection, then the connection structure is simplified, but insulation failure may occur due to contact with the base plate edge

Engineering Contradiction:

Improveconnection structure complexityVSAvoidmechanical damage to wire insulation

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The groove acts as a protective intermediary structure that intercepts the wire leading portion before it can contact the harmful outer peripheral edge. This adds minimal structural complexity while effectively eliminating the mechanical damage risk

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The groove is pre-formed on the base plate side surface to provide a protected pathway in advance. This beforehand preparation ensures that when the wire is routed, it automatically follows the protected path without requiring additional protective measures during assembly

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20250157723A1Coil device

Publication Date: 2025.05.15 TDK CORP

AI summary

A coil device includes a core including a winding core portion, a winding portion of a wire disposed in a coil shape around the winding core portion, and a base plate provided with a terminal to which a leading portion of the wire led out from the winding portion is attached. The core is disposed on a first surface as one surface of the base plate. A wire connection portion of the terminal is disposed on a second surface as the other surface of the base plate located opposite to the first surface. The base plate is provided with a base-side passage for passing and guiding the leading portion of the wire from the winding portion to the wire connection portion.