Coil Core Curvature for Miniaturized Mountable Components

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Solution Overview

Problem

As the size of coil components decreases, the deflection strength of the core is compromised due to reduced thickness of the winding core and flange portions, making them prone to mechanical stress and mounting issues on circuit boards.

Innovation Solution

Incorporating a curved portion at the connection between the winding core and flange portions, with a specific curvature ratio between 20% to 60% in the height direction, to enhance flexural strength and prevent excessive thinning of flange portions, allowing for appropriate mounting on circuit boards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the size of the coil component is decreased, then the compactness is improved, but the deflection strength of the core deteriorates

Engineering Contradiction:

Improvesize of coil componentVSAvoiddeflection strength of core

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent applies curvature by forming a curved portion at the connection between the winding core and flange portions. This curved structure increases the deflection strength without increasing the overall component size, effectively resolving the contradiction between miniaturization and structural strength.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent changes the geometric parameters of the core structure by introducing a curved portion with a specific height ratio (20%-60% of the distance from the bottom surface to the terminal electrode). This parameter optimization allows the core to maintain adequate deflection strength while keeping the component size reduced.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If the thickness of the winding core portion and flange portions is decreased, then the component size is reduced, but the mechanical strength deteriorates

Engineering Contradiction:

Improvethickness of winding core portionVSAvoidmechanical strength

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The curved portion at the connection between the winding core and flange portions compensates for the reduced thickness by distributing mechanical stress more effectively. The curvature geometry provides structural reinforcement without increasing the thickness dimensions.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Strength

If the length of the first curved portion is increased, then the flexural strength is improved, but the thickness of the first flange portion increases

Engineering Contradiction:

Improveflexural strengthVSAvoidthickness of first flange portion

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The patent optimizes the height of the curved portion to be within 20%-60% of the distance from the bottom surface of the winding core to the terminal electrode. This parameter control ensures adequate flexural strength while preventing excessive increase in flange portion thickness.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11875927B2Coil component

Publication Date: 2024.01.16 MURATA MFG CO LTD

AI summary

A coil component includes a core including a winding core portion and a first flange portion that is disposed on a first end portion of the winding core portion in a direction in which the winding core portion extends. A first curved portion is formed at a connection between a bottom surface of the winding core portion and the first flange portion. A ratio of a length of the first curved portion in a height direction to a distance in the height direction between the bottom surface and a first terminal electrode is no less than 20% and no more than 60% (i.e., from 20% to 60%).