Coil Component Winding Core Recessed Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The mechanical strength of winding cores in coil components decreases as their size decreases, leading to potential breakage, especially at joints between the winding core and flange portions, due to the use of sintered magnetic material powder.
Innovation Solution
Incorporating recessed portions on the upper surfaces of the flange portions and forming protrusions within these recessed areas to enhance the mechanical strength of the winding core, particularly at joints, while maintaining a sufficient adhesive contact with the plate core for improved electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of the coil component is decreased, then the electrical characteristics are improved, but the mechanical strength of the winding core decreases
Solution Approach 1:
The patent applies local quality by creating a recessed portion specifically at the joint between the winding core and flange portion, where mechanical strength is most needed. This localized structural modification strengthens the critical joint area without increasing the overall size of the coil component, thus maintaining improved electrical characteristics while addressing the mechanical strength weakness at the specific location where breakage is most likely to occur.
2Reliability
If the winding core portion is narrowed to decrease the circumferential length of the wire, then the number of turns increases and electrical characteristics improve, but the mechanical strength decreases
Solution Approach 1:
The patent applies local quality by creating a recessed portion specifically at the joint between the winding core and flange portion, where mechanical strength is most needed. This localized structural modification strengthens the critical joint area without increasing the overall size of the coil component, thus maintaining improved electrical characteristics while addressing the mechanical strength weakness at the specific location where breakage is most likely to occur.
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 enhanced mechanical strength of the winding core and improved joint integrity allow for a smaller coil component size without compromising electrical performance, including increased inductance values and reduced variations in radio frequency performance.
Implementation Method 1
The technique disclosed in Japanese Unexamined Patent Application Publication No. 2014-99587 enables a capillary phenomenon to occur in the gaps near the flat surface 8 of the central portion of the upper surface 7 and enables space between the first flange portion 3 and the plate core 4 to be filled with the adhesive 6 in the minimum amount.
Data Source
AI summary
A coil component includes a winding core that includes a winding core portion, a first flange portion, and a second flange portion. The coil component further includes a plate core that has a main surface facing the winding core portion, the first flange portion, and the second flange portion, that extends between the first flange portion and the second flange portion, and that is secured to the winding core by using adhesive. Each of the first flange portion and the second flange portion has an upper surface that faces the main surface of the plate core. Recessed portions are formed on the corresponding upper surfaces. Protrusions may be formed in corresponding regions in which the recessed portions are formed.