Coil Component Curved Flange Gap Stability
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Solution Overview
Problem
Existing coil components with drum-like and plate-like cores face variations in magnetic gap volume due to improper positioning of the plate-like core, leading to fluctuations in electrical characteristics such as inductance and impedance.
Innovation Solution
The coil component features a drum-like core with flange parts having bent top surfaces that maintain a constant magnetism gap volume despite variations in plate-like core inclination, achieved through a minute clearance for adhesive penetration and strategically designed bent shapes on both flange parts and the plate-like core, reducing the need for precise posture control during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat face is formed in the central portion of the flange part top surface with a gradient to the end portions, then adhesive penetration is improved and adhesion strength is increased, but the magnetism gap volume varies significantly when the plate-like core positioning deviates from the ideal position
Solution Approach 1:
The patent applies curvature to the flange part top surface by forming a convex curved surface instead of a flat face. This curved surface has a vertex at the central portion and extends toward the end portions, creating a gradual height variation that facilitates adhesive penetration while maintaining consistent magnetism gap volume even when the plate-like core positioning deviates from the ideal position. The curved geometry compensates for positioning variations, ensuring stable magnetic characteristics.
2Ease of manufacture
If the plate-like core is allowed to be positioned with broader tolerance, then manufacturing complexity and costs are reduced, but the magnetism gap volume and electrical characteristics become unstable
Solution Approach 1:
The convex curved surface on the flange part top surface creates a self-aligning effect. When the plate-like core is positioned within a broader tolerance range, the curved geometry ensures that the magnetism gap volume remains substantially constant regardless of the exact positioning. The vertex of the curved surface is positioned at a height that maintains the desired gap, while the curved slopes provide tolerance for lateral and angular deviations.
3Strength
If a minute clearance is created for adhesive penetration, then adhesive distribution is improved and bonding is enhanced, but the structure becomes more sensitive to positioning variations
Solution Approach 1:
The convex curved surface geometry creates optimal clearance conditions for adhesive penetration. The curved surface vertex at the central portion provides a controlled minimum gap, while the sloping surfaces toward the end portions gradually increase the clearance, facilitating uniform adhesive distribution. This curved geometry simultaneously compensates for positioning variations, reducing sensitivity to manufacturing tolerances.
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 stabilizes the magnetic gap volume and inductance, reducing manufacturing complexity and costs by allowing broader tolerance in positioning the plate-like core relative to the drum-like core, thereby enhancing direct current superposition characteristics and inductance.
Implementation Method 1
a capillary phenomenon can be caused in the central portion of the top surface in the clearance and thus, the gap between the flange part and the plate-like core can be filled with the smallest possible amount of adhesive
Data Source
AI summary
A bent shape that projects when viewed in an axis direction of a winding core part is given to each top surface of a first flange part and a second flange part of a drum-like core. The top surface and a lower principal surface of a plate-like core are closest to each other in a portion where a vertex of the bent shape is positioned.