Asymmetric Terminal Electrodes for Coil Component Eddy Current Reduction
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Solution Overview
Problem
Existing coil components with drum-shaped cores face challenges in reducing eddy current loss and ensuring reliable solder fillet formation on the outer surface of the flange, particularly in on-vehicle applications, where terminal electrodes are not formed on the outer surface, leading to increased eddy current loss and potential short circuits.
Innovation Solution
A coil component design featuring terminal electrodes on the outer surface of the flange with specific spacing and layout configurations to minimize eddy current loss, including L-shaped metal fittings and a plate core for reduced manufacturing costs and enhanced magnetic characteristics, ensuring non-overlapping terminal electrodes with the winding core and strategic placement to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal electrode is formed on the outer surface of the flange to form a solder fillet, then reliability is improved, but eddy current loss increases
Solution Approach 1:
The patent applies asymmetry by positioning terminal electrodes asymmetrically on the flange outer surface. Specifically, terminal electrodes are arranged at different radial distances from the center axis, with some electrodes positioned closer to the center and others farther away. This asymmetric arrangement breaks the symmetry of eddy current paths, effectively reducing eddy current loss while still providing terminal electrodes for reliable solder fillet formation on the outer surface.
2Reliability
If the distance between terminal electrodes is reduced to prevent short circuits, then reliability is improved, but eddy current loss increases
Solution Approach 1:
The patent resolves this contradiction by implementing asymmetric electrode positioning where terminal electrodes are placed at non-uniform intervals from the center axis. This creates unequal eddy current path lengths and resistances, reducing overall eddy current loss while maintaining adequate spacing between electrodes to prevent short circuits. The asymmetric layout optimizes both reliability and energy efficiency simultaneously.
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 design effectively reduces eddy current loss and prevents short circuits while allowing for reliable solder fillet formation, enhancing the reliability and performance of coil components in compact electronic devices, such as on-vehicle systems.
Implementation Method 1
eddy current loss increase when a terminal electrode is formed on the outer surface of a flange
Data Source
AI summary
Disclosed herein is a coil component that includes a drum-shaped core having a first flange part provided at one end of a winding core part, first to fourth terminal electrodes formed on the first flange part so as to be arranged in this order in a second direction, and first to fourth wires wound around the winding core part. One ends of the first to fourth wires are connected to different ones of the first to fourth terminal electrodes. The first and second terminal electrodes are not symmetrical with the third and fourth terminal electrodes so that the third and fourth terminal electrodes are offset outward compared with the first and second terminal electrodes.