Coil Core Flange Structure for Dispersing Mounting Stress
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Solution Overview
Problem
Conventional coil components experience damage to connecting portions between flanges and the winding core due to force from the mount substrate, leading to reduced strength.
Innovation Solution
The design includes a winding core with flanges having inclined surfaces that intersect at positions separated along the axis of the core, dispersing stress and enhancing the core's strength by eliminating the concentration of force at a single intersection point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first surfaces of the flanges face the mount substrate during mounting, then the coil component can be mounted on the substrate, but the connecting portions between the inner-side end surfaces of the flanges and end portions of the winding core are damaged due to concentrated force
Solution Approach 1:
The inner-side end surface of the flange is divided into multiple inclined surfaces (first inclined surface and second inclined surface) that are separated along the axis direction. This segmentation distributes the mounting force from the substrate across multiple distinct contact regions rather than concentrating it at a single intersection point, thereby preventing damage to the connecting portions while maintaining mounting capability
Solution Approach 2:
The inclined surfaces are arranged in the axial direction (length dimension) rather than overlapping in the radial direction. By separating the contact points along the axis dimension, the design transforms a single-point stress concentration problem into a distributed multi-point stress distribution system, improving the strength of connecting portions while preserving ease of mounting
Data Source
AI summary
A core includes a winding core, a first flange at a first end portion of the winding core, and a second flange at a second end portion of the winding core. The winding core has first and second surfaces on opposite sides, and first and second side surfaces intersecting the first and second surfaces and on opposite sides. The first flange has first and second surfaces on opposite sides, first and second side surfaces intersecting the first and second surfaces and located on opposite sides, an inner-side end surface connected to the first end portion of the winding core, and an outer-side end surface on an opposite side from the winding core. The inner-side end surface of the first flange has a first inclined surface between the first surface of the winding core and the first surface of the first flange.