Coil Component Orientation Marker via Liquid Resin Bath
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Solution Overview
Problem
The miniaturization of coil components makes it difficult to fill the wound area with resin and determines the correct orientation for mounting, leading to potential mounting errors due to reduced visibility and increased manufacturing complexity.
Innovation Solution
A coil component with a core, terminal electrodes, and an insulating resin layer, where a marker is formed from the same material as the resin on the flanges to facilitate resin injection and ensure correct orientation during mounting, using a method that involves winding the coil, connecting ends to electrodes, and immersing the flanges in a liquid resin bath to form a resin coating and marker.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the core size is reduced to increase mounting density, then the size of the coil component is reduced, but it becomes more difficult to fill the wound area with resin
Solution Approach 1:
The method performs preliminary action by immersing the flanges in liquid resin before the wound area is completely formed. The liquid resin is applied to the flanges first, then the winding is performed, allowing the resin to be drawn into the wound area through capillary action during and after winding. This preliminary resin application ensures adequate resin filling even in miniaturized components where post-winding injection is difficult.
Solution Approach 2:
The invention utilizes capillary action (a hydraulic principle) to draw liquid resin from the flanges into the wound area. By immersing the flanges in liquid resin bath, the resin is drawn through capillary forces into the tight spaces of the wound winding, ensuring complete filling without requiring high-pressure injection that would be difficult in miniaturized components.
2Volume of moving object
If the core size is reduced to increase mounting density, then the size of the coil component is reduced, but it becomes more difficult to visually determine the position and orientation during mounting
Solution Approach 1:
The invention applies color changes by forming a marker on the flanges using liquid resin that has a different appearance from the insulating resin. The marker is created by immersing the flanges in liquid resin before winding, and after curing, the marker region has distinct visual characteristics that enable easy identification of correct mounting orientation and position during assembly.
3Difficulty of detecting and measuring
If the shape of the core is changed or a marker is added to indicate orientation, then the correct orientation can be confirmed, but the manufacturing process becomes more complex with additional steps
Solution Approach 1:
The invention merges the marker formation process with the insulating resin application process. Both the insulating resin and the orientation marker are applied simultaneously by immersing the flanges in liquid resin before winding. The marker is formed as part of the same resin coating process, eliminating the need for separate marker application steps and reducing manufacturing complexity while still providing clear orientation indication.
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 solution allows for easier resin injection and reduces mounting errors by providing a visible marker for correct orientation, enhancing the reliability of coil component mounting and preventing short-circuiting in densely packed configurations.
Implementation Method 1
immersing a portion of the outer peripheral surface of the pair of flanges in a liquid resin bath to form a resin coating over the wound portion of the winding within the winding accommodating region
Data Source
AI summary
A coil component having an easily discernible orientation, and a method of producing such a coil component that facilitates the injection of resin. A coil component includes a core with a winding portion, first and second flanges disposed on either end of the winding portion, and a winding accommodating region defined by the winding portion and the first and second flanges, terminal electrodes disposed on the second flange and a winding wound about the winding portion and connected to the terminal electrodes. An insulating resin is formed over the winding at the winding accommodating region. A marker made from a material the same as the insulating resin is provided at outer peripheral surface of the flanges.