Coil Component Asymmetrical Marks Core Alignment
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Solution Overview
Problem
Conventional coil components with a plate-shaped core face challenges in determining proper assembly of the first and second cores due to the simplicity of the core shape, leading to complications in manufacturing and electrical characteristic measurement, especially when the cores are rotated by 90 degrees, which results in similar electrical characteristics for both proper and improper postures.
Innovation Solution
The coil component incorporates a second core with an outside surface featuring marks that change arrangement when rotated by 90 degrees and an inside surface with undulating marks that alter the magnetic path when the cores are misaligned, allowing for easy detection of proper assembly through electrical characteristic measurement, such as inductance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the second core has a simple plate shape, then the manufacturing process is simplified, but it becomes difficult to determine whether the first and second cores are properly assembled
Solution Approach 1:
The patent applies mark formation on the second core that changes its appearance or arrangement based on orientation. The marks are positioned such that they are visible in specific orientations, enabling visual detection of proper assembly posture without complicating the core shape itself.
Solution Approach 2:
The patent introduces asymmetric mark arrangements on the second core. The marks are positioned asymmetrically so that only one specific orientation presents the correct mark arrangement, allowing easy visual identification of proper assembly while maintaining the simple plate shape of the core.
2Area of stationary object
If the second core is square-shaped when viewed from the normal direction, then the mounting area is minimized, but electrical characteristics become similar in both proper and improper postures
Solution Approach 1:
The patent uses marks on the second core that create visual differentiation based on orientation. These marks allow the mounting machine to recognize the correct posture, compensating for the lack of electrical characteristic differentiation in square-shaped cores.
Solution Approach 2:
The patent introduces marks as an intermediary element that mediates between the square core shape and the detection requirement. The marks provide the necessary orientation information that the square core shape alone cannot provide through electrical characteristics.
3Ease of operation
If marks are formed only on the outside surface of the second core, then the mounting machine can recognize posture, but assembly properness cannot be determined through electrical measurement
Solution Approach 1:
The patent divides the mark system into two segments: outside marks on the outside surface for posture recognition by the mounting machine, and inside marks on the inside surface for assembly verification through electrical measurement. This segmentation allows each mark type to serve its specific function independently.
Solution Approach 2:
The patent applies different mark characteristics to different locations on the second core. Outside marks have properties optimized for visual detection from the exterior, while inside marks have properties optimized for affecting electrical characteristics when properly positioned, allowing each location to serve its specific detection purpose.
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
This design enables straightforward determination of proper core alignment by measuring electrical characteristics, enhancing productivity and reducing manufacturing complexity by differentiating between proper and improper postures based on inductance changes.
Implementation Method 1
measuring electrical characteristics such as inductance
Implementation Method 2
an inside mark with undulation is formed on the inside surface of the second core and designed to change its arrangement at the time of rotating the second core by 90 degrees
Data Source
AI summary
A coil component includes a first core, a second core, a lead wire, an outside mark, and an inside mark. The first core includes a winding portion and a pair of core ends. The second core connects a pair of the core ends and includes an inside surface and an outside surface. The lead wire is wound around the winding portion. The outside mark is formed on the outside surface of the second core and designed to change its arrangement at the time of rotating the second core by 90 degrees in a rotational direction whose central axis is along a normal direction of the outside surface. The inside mark with undulation is formed on the inside surface of the second core and designed to change its arrangement at the time of rotating the second core by 90 degrees in the rotational direction.