Coil Component Dummy Terminal Adhesive Bonding
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Solution Overview
Problem
Conventional coil components lack sufficient durability against vibration and impact, necessitating an improvement in this area.
Innovation Solution
A coil component design featuring a core with a spiral coil conductor and a dummy terminal that includes a top, bottom, and side part with openings filled with adhesive, providing enhanced bonding and stress distribution to improve durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional coil component structure is used, then the device complexity is low, but the durability against vibration and impact is insufficient
Solution Approach 1:
The dummy terminal serves multiple functions: it acts as a mechanical anchor for adhesive bonding to improve vibration and impact durability, while also providing an external terminal function for electrical connection. This multi-functionality resolves the contradiction by enhancing reliability without requiring entirely separate structural elements.
Solution Approach 2:
The dummy terminal is divided into distinct functional parts: a bottom part for adhesive bonding to the core, a side part extending along the core surface, and a top part forming the external terminal. This segmentation allows each part to optimize its specific function while working together to improve overall durability without excessive complexity.
2Strength
If the dummy terminal is bonded to the core at the bottom part, then the bonding strength is improved, but the stress concentration increases under vibration and impact
Solution Approach 1:
The bonding interface is extended from a single-point or small-area bond to a distributed three-dimensional structure. The dummy terminal's side part bonds along the lateral surface of the core, distributing stress across multiple locations and reducing stress concentration while maintaining strong overall bonding.
Solution Approach 2:
Different parts of the dummy terminal have different bonding characteristics: the bottom part provides strong adhesive bonding to the core surface, while the side part distributes bonding along the core's lateral surface. This local differentiation optimizes both bonding strength and stress distribution.
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 significantly enhances the coil component's durability against vibration and impact by distributing stress through the adhesive-filled openings, thereby increasing resistance to shearing forces and ensuring secure mounting on a circuit board.
Implementation Method 1
an adhesive filled in the opening in the dummy terminal
Data Source
AI summary
In an embodiment, a coil component includes: a core 10; a coil conductor 40 having a spiral part 42 placed inside the core 10, and a lead part 48 which is led out from the spiral part 42 to the principal outer surface, constituting the bottom face 28, of the core 10, and which includes an end part 46 that serves as an external terminal 49; an insulated terminal 60 electrically insulated from the coil conductor 40, which is fitted onto and bonded to the core 10, and which has a bottom part 64 positioned on the bottom face 28, a top part 62 positioned on the top face 26, and a side part 66 coupling the bottom part 64 and the top part 62, where the top part 62 and side part 66 have an opening 68 in which an adhesive 82 is filled.