Coil Component Insulative Layer Protrusion for Positional Stability
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Solution Overview
Problem
Existing coil components experience positional instability due to thermal history and vibration, leading to changes in inductance, as they lack effective insulation and adhesion mechanisms to maintain coil position within the element body.
Innovation Solution
A coil component design featuring a ring-shaped planar coil portion with an intra insulative layer and an extra insulative layer that protrudes from the inner and outer peripheral edges of the superimposing region, enhancing adhesion with the covering portion by increasing contact area and intruding into the covering portion, thereby improving positional stability and preventing inductance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional insulative layer is used to cover the coil-wound portion, then the coil portion is protected, but the contact area with the covering portion is insufficient, resulting in poor adhesion and positional instability
Solution Approach 1:
The insulative layer is extended in the vertical dimension to create a protrusion region that intrudes into the covering portion. This dimensional extension transforms a two-dimensional contact interface into a three-dimensional interlocking structure, significantly increasing the contact area and improving adhesion between the insulative layer and covering portion.
Solution Approach 2:
The protrusion region of the insulative layer is designed to intrude into and be nested within the covering portion. This nesting configuration creates an interlocking structure where the insulative layer is partially embedded in the covering portion, enhancing mechanical bonding and preventing positional deviation of the coil portion.
2Volume of moving object
If the insulative layer is made thinner to reduce size, then the component becomes more compact, but the adhesion strength with the covering portion decreases, leading to coil positional deviation under thermal and vibrational stress
Solution Approach 1:
Instead of increasing the horizontal thickness of the insulative layer, the solution extends the layer vertically to create a protrusion region. This allows the insulative layer to maintain thin horizontal dimensions for compactness while achieving sufficient adhesion strength through the vertical intrusion into the covering portion.
Solution Approach 2:
The insulative layer is designed with non-uniform thickness, featuring a protrusion region with increased vertical dimension at specific locations. This local quality enhancement concentrates the adhesion-strengthening function in the protrusion region while keeping other areas of the insulative layer thin, thus achieving both compactness and strong adhesion.
3Reliability
If the coil portion is firmly fixed to prevent positional deviation, then inductance stability is improved, but the manufacturing process becomes more complex and difficult
Solution Approach 1:
The insulative layer's protrusion region is designed to automatically intrude into the covering portion during the standard manufacturing process, creating self-fixing adhesion without requiring additional fixation steps. The structure itself provides the fixing function, eliminating the need for complex external fixation mechanisms and maintaining ease of manufacture.
Solution Approach 2:
The fixing function is merged into the insulative layer structure itself by creating the protrusion region. Instead of separating the insulation function and the fixing function into different components, the design combines both functions in a single integrated structure, simplifying the overall manufacturing process while ensuring inductance stability.
Data Source
AI summary
Provided is a coil component including a coil portion that has at least one layer of ring-shaped planar coil portion including a coil-wound portion and an insulative resin layer which covers the periphery of the coil-wound portion within the same layer as the coil-wound portion, and an insulative resin layer overlapping the planar coil portion; and a covering portion that covers the coil portion. The insulative resin layer has a superimposing region overlapping a forming region of the planar coil portion and a protrusion region protruding from at least any one of an inner peripheral edge and an outer peripheral edge of the superimposing region, when viewed in the direction of overlapping the planar coil portion.