Coil Component Magnetic Core Positioning via Metallic Pins
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Solution Overview
Problem
Existing coil components face challenges in achieving accurate positioning of magnetic cores and coil electrodes, leading to potential contact and stress on the magnetic core, which deteriorates coil characteristics and limits the reduction in size and increase in inductance.
Innovation Solution
The coil component employs metallic pins with solder fillet-like support portions to accurately position the magnetic core, maintaining a small gap and reducing stress, allowing for increased inductance and reduced size while preventing unnecessary contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the gap between the magnetic core and coil electrode is reduced to decrease component size, then the size of the coil component is reduced, but the coil electrode may come into contact with the magnetic core causing stress and deterioration of coil characteristics
Solution Approach 1:
The patent introduces an insulating layer as an intermediary between the coil electrode and the magnetic core. This insulating layer prevents direct contact while allowing the components to be positioned close together, thus reducing the overall component size without compromising coil characteristics or causing stress on the magnetic core.
2Reliability
If the number of turns of the coil electrode is increased to improve inductance, then the inductance of the coil component is improved, but the component size increases and manufacturing complexity increases
Solution Approach 1:
The patent transitions from planar wiring patterns to three-dimensional vertically arranged metallic pins for the coil electrode. This dimensional change allows the coil electrode to be wound around the magnetic core in a compact vertical configuration, achieving high inductance with more turns while maintaining a small component footprint.
Solution Approach 2:
The coil electrode is segmented into multiple metallic pins arranged vertically around the magnetic core. Each pin represents a segment of the coil structure, allowing the total number of turns to be distributed across multiple vertical elements rather than requiring a large planar area, thus achieving high inductance in a compact size.
3Reliability
If accurate positioning of the magnetic core and coil electrode is achieved, then coil characteristics are improved, but manufacturing precision requirements increase
Solution Approach 1:
The insulating layer serves as a positioning intermediary that defines the precise spatial relationship between the coil electrode and magnetic core. By controlling the thickness and position of this insulating layer, accurate positioning is achieved without requiring extremely tight manufacturing tolerances on the components themselves, thus improving coil characteristics while managing manufacturing precision requirements.
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 configuration improves coil characteristics by reducing parasitic inductance, maintaining insulation, and enabling a smaller size with enhanced inductance, while minimizing stress on the magnetic core.
Implementation Method 1
Support portions, each of which is formed of solder in a fillet-like shape, are provided between peripheral surfaces of the first end portions of the metallic positioning pins and the corresponding mount electrodes
Data Source
AI summary
An improvement in coil characteristics is achieved by performing accurate positioning of a magnetic core. A coil component 2 includes a wiring substrate 3, a magnetic core 4 that has a ring-like shape and that is disposed on a bottom surface of the wiring board 3, and a coil electrode 5 that is wound around the magnetic core 4, and the coil electrode 5 includes a plurality of inner metallic pins 11a and outer metallic pins 11b that are vertically arranged around the magnetic core 4. First end portions of the plurality of inner and outer metallic pins 11a and 11b are each connected, with solder, to an end surface of a corresponding one of a plurality of via conductors 9a, the end surface being exposed at the bottom surface of the wiring board 3.