Coil Component Top Plate Spacer Design for Polishing Damage Prevention
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Solution Overview
Problem
The existing coil components face fluctuations in characteristics due to damage from the barrel polishing process, which affects the stability of inductance values and magnetic saturation, caused by the scraping of projections during polishing.
Innovation Solution
The coil component design includes convex spacer portions on the top plate that connect to form a large convex area, preventing damage during polishing and enhancing mechanical strength without increasing the component's size, by using a thick stage portion that faces the winding core and dividing spacer portions to reduce magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If barrel polishing is performed to remove burrs, then surface quality is improved, but the projections on the top plate are scraped and damaged causing characteristic fluctuations
Solution Approach 1:
The top plate is segmented into a body portion and protruding portions (projections). The projections are designed as separate functional elements that extend from the body, allowing them to be distinguished from the main structure. This segmentation enables the projections to maintain their integrity during polishing while the body portion receives the polishing treatment.
Solution Approach 2:
The projections are pre-formed with a specific shape and size before the polishing process. By establishing the projection geometry in advance (preliminarily), the design ensures that even if some material is removed during polishing, the projections retain their essential form and function, preventing characteristic fluctuations.
2Reliability
If gaps are provided between the top plate and flange portions to prevent magnetic saturation, then DC superimposition characteristics are improved, but the projections may be damaged during polishing
Solution Approach 1:
The top plate exhibits local quality differentiation: the body portion has a certain thickness for structural integrity, while the projections extend further to create the necessary gaps. This local variation in geometry allows the projections to fulfill the gap-function for preventing magnetic saturation while being designed with sufficient robustness to withstand polishing.
Solution Approach 2:
The projections extend beyond the minimum required gap distance, providing an excessive amount of material that ensures the gap function is fulfilled even if some material is removed during polishing. This partial excess action guarantees that the DC superimposition characteristics are maintained while protecting against projection damage.
3Volume of moving object
If the top plate is made thinner to reduce component size, then miniaturization is achieved, but mechanical strength during mounting is reduced
Solution Approach 1:
Instead of increasing the thickness of the entire top plate (which would increase component size in one dimension), the design adds protruding portions that extend in another dimension (radially outward from the body). This dimensional change allows the top plate to maintain thinness for miniaturization while the projections provide the necessary mechanical strength for mounting.
Solution Approach 2:
The top plate is segmented into a thin body portion for miniaturization and separate protruding portions for mechanical strength. This segmentation allows each part to fulfill its specific function: the body maintains small overall dimensions while the projections provide mounting strength without increasing the core component size.
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 electric characteristics, such as inductance values, and increases mechanical strength, particularly during mounting, while maintaining the component's size and improving DC superimposition characteristics.
Implementation Method 1
Gaps are provided between the top surfaces of the first flange portion and the second flange portion and the lower main surface of the top plate to make magnetic saturation less likely to occur, thereby improving the DC superimposition characteristics
Data Source
AI summary
A coil component includes a core having first and second flange portions, and a top plate. Convex first and second spacer portions are in a lower main surface of the top plate that faces the first and second flange portions and are in contact with top surfaces of the first and second flange portions to form gaps between the top surfaces of the flange portions and the lower main surface of the top plate. A stage portion is in a region of the lower main surface of the top plate that faces the winding core portion of the core, and the first and second spacer portions are connected to each other via the stage portion. The spacer portions and the stage portion form a convex portion having a relatively large area to prevent the spacer portions from being scraped and damaged in a polishing process for deburring or chamfering.