Coil Component Dual Hardness Securing Parts
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Solution Overview
Problem
Conventional coil components with a drum core housed in a ring core face challenges in achieving high reliability and stability due to difficulties in evenly applying adhesive and susceptibility to heat stress, leading to uneven gaps and stress distribution, especially with thick conductive wires.
Innovation Solution
The coil component incorporates a drum core with pair of flange parts, a conductive wire wound around it, a ring core with a through hole housing the drum core, and includes a first securing part covering the outer side of a second securing part with higher hardness, arranged to suppress fluctuation between the cores, ensuring high reliability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied over the entire circumference of the gap between the ring core and drum core, then impact resistance is improved, but manufacturing precision deteriorates due to difficulty in even application and positioning
Solution Approach 1:
The adhesive application is divided into two distinct segments: a first adhesive applied at specific positions (e.g., upper portion) and a second adhesive applied at other positions (e.g., lower portion). This segmentation allows each adhesive to be applied precisely at its designated location without the difficulty of achieving uniform circumferential application, while collectively providing comprehensive impact resistance.
Solution Approach 2:
Different adhesives with different properties are used at different locations. The first adhesive and second adhesive may have different hardness values, viscosities, or curing characteristics optimized for their specific positions. This local differentiation allows each adhesive to perform its function optimally while maintaining precise positioning control.
2Strength
If adhesive is applied over the entire circumference, then impact resistance is improved, but reliability deteriorates due to susceptibility to heat stress and uneven gap formation
Solution Approach 1:
The adhesive system is segmented into first and second adhesives applied at different positions around the gap. This segmentation allows thermal stress to be distributed across multiple adhesive joints rather than concentrated in a continuous adhesive layer, reducing the risk of thermal degradation and improving reliability under heat stress conditions.
Solution Approach 2:
The patent uses composite adhesive systems where first and second adhesives with different material properties are combined. This composite approach allows optimization for both impact resistance and thermal stability, as each adhesive can be selected for its specific strength profile, creating a more reliable overall bonding system.
3Quantity of substance
If thick conductive wire is used, then electrical conductivity is improved, but positioning precision deteriorates due to drum core movement during lead wire processing
Solution Approach 1:
Adhesives are applied to secure the drum core in position before lead wire processing operations are performed. This preliminary securing action prevents drum core movement during subsequent lead wire bending and connection processes, maintaining positioning precision even when using thick conductive wires that require extensive lead wire processing.
Data Source
AI summary
In an embodiment, a coil component 10 has a drum core 20 housed in a through hole 32 of a ring core 30, and two types of securing parts are provided in a gap G between an outer circumference of one flange part 24 of the drum core 20 and an inner circumference of the through hole 32. Terminal electrodes 50A, 50B connecting to ends 46A, 46B pulled out from a winding wire 40 wound around the drum core 20 are assembled to the ring core 30. Second securing parts 60A, 60B are arranged to opposite to each other with respect to a center C of the flange part 24, and first securing parts 62A, 62B are provided to cover an outer side of the second securing parts 60A, 60B. A hardness of the second securing part is higher than that of the first securing part.