Coil Component Vibration Reliability via Embedded Lead Wire Tips
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Solution Overview
Problem
Existing coil components face reliability issues due to vibration, as terminal parts with lead wires are not securely fixed to the element body part, leading to potential disconnection when subjected to external forces.
Innovation Solution
The coil component design embeds tip parts of lead wires and relay parts within the element body part, with terminal parts joined to these embedded sections, ensuring secure attachment and reduced exposure to external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal parts are bent to extend from side faces to bottom face of element body part, then the coil component can be assembled, but vibration reliability deteriorates due to large forces on exposed lead wire areas
Solution Approach 1:
The patent extracts the vulnerable lead wire section from the exposed exterior position and embeds it within the element body part. By taking out the lead wire tip and placing it inside the element body, the design eliminates the harmful exposure to external forces while maintaining the terminal connection function.
Solution Approach 2:
The patent applies nesting by embedding the lead wire tip and relay part inside the element body part. The lead wire structure is nested within the element body, with the tip part and relay part housed inside, protecting them from external vibration forces while maintaining electrical connectivity.
2Strength
If lead wires are led out onto exterior of element body part, then connection to terminal parts is achieved, but joining strength deteriorates under vibration
Solution Approach 1:
The patent applies preliminary action by embedding the lead wire tip and relay part inside the element body part before the final assembly is completed. This preliminary positioning protects the connection points from vibration forces before they are subjected to operational stress, preventing disconnection.
3Reliability
If terminal parts are not fixed to element body part, then manufacturing is simpler, but vibration resistance deteriorates
Solution Approach 1:
The patent merges the lead wire tip, relay part, and element body part into a single integrated structure by embedding them together. This combining eliminates the need for separate fixing mechanisms while providing inherent vibration resistance through the integrated design.
Data Source
AI summary
In an exemplary embodiment, a coil component includes: an element body part 10 that is formed containing a magnetic material; a coil 40 that is embedded within the element body part 10 and constituted by a wound conductive wire; lead wires 44a, 44b that are extended from the conductive wire and are led out from the coil 40; and terminal parts 70a, 70b that are joined to the lead wires 44a, 44b; wherein tip parts 46a, 46b of the lead wires 44a, 44b, each having a prescribed length from the tip, are embedded in the element body part 10 and also extend along the bottom face 22 of the element body part 10, and the terminal parts 70a, 70b are joined to the tip parts 46a, 46b of the lead wires 44a, 44b on the bottom face 22 of the element body part 10.