Coil Component Terminal Recess for Solder Heat Isolation
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Solution Overview
Problem
Conventional coil components face reliability issues due to heat from solder affecting welding and adhesive connections between metal terminals and wires/flange portions, leading to potential connection failures.
Innovation Solution
The coil component design positions the wire connecting and flange connecting portions on the top surface side of the flange portion's peripheral surface, within a recess, to prevent heat from soldering and adhesives from reaching these critical areas, ensuring reliable connections between metal terminals and wires/flange portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the welding parts are positioned on the bottom surface side of the flange portions, then the manufacturing process is simplified, but the connection reliability between metal terminals and wire deteriorates due to solder heat affecting the welding parts
Solution Approach 1:
The patent moves the welding parts from the bottom surface (z-axis position) to the peripheral surface (radial dimension), changing the spatial dimension of connection parts. This dimensional transition allows welding parts to be positioned away from the soldering heat zone while maintaining manufacturing simplicity through automated wire feeding and welding processes.
Solution Approach 2:
The patent segments the flange portion into distinct functional zones: the bottom surface for mounting, the peripheral surface for wire connections, and the top surface for terminal connections. This segmentation isolates the welding parts from solder heat while maintaining ease of manufacture through specialized process zones.
2Ease of manufacture
If the adhesion parts are positioned on the bottom surface side of the flange portions, then the assembly process is simplified, but the connection reliability between metal terminals and flange portions deteriorates due to solder heat affecting the adhesive
Solution Approach 1:
The patent relocates adhesion parts from the bottom surface (z-axis position) to the peripheral surface (radial dimension), transitioning the bonding interface to a dimension away from thermal exposure. This maintains assembly simplicity while protecting adhesive integrity from solder heat.
Solution Approach 2:
The patent creates distinct functional zones on the flange portion, placing adhesive bonding interfaces on the peripheral surface separate from the bottom surface mounting zone. This segmentation protects temperature-sensitive adhesive bonds from thermal exposure during soldering while maintaining assembly efficiency.
3Reliability
If the wire connecting portion and flange connecting portion are positioned on the top surface side of the peripheral surface, then connection reliability is improved by avoiding solder heat, but the device complexity increases due to the need for recess structures
Solution Approach 1:
The patent merges the wire connecting portion and flange connecting portion into a single recess structure on the peripheral surface. This integration reduces the number of separate components and simplifies the overall device structure while maintaining high connection reliability through thermal isolation.
Solution Approach 2:
The patent nests the wire and flange connections within a recess structure, placing connecting portions inside the recess to protect them from solder heat. This nesting approach maintains structural simplicity while achieving thermal protection and reliable connections.
Data Source
AI summary
A coil component has a pair of flange portions including a bottom surface that may be mounted on a mounting substrate and a top surface opposite to the bottom surface, a winding core portion coupling the pair of the flange portions, a top plate attached to the top surface of the flange portions, a metal terminal attached to each of the flange portions, and a wire wound around the winding core portion and electrically connected to the metal terminal. The metal terminal has a wire connecting portion connected to the wire and a flange connecting portion connected to the flange portion, and the wire connecting portion and the flange connecting portion are each located on the top surface side of a peripheral surface positioned between the bottom surface and the top surface of the flange portion.