Coil Component Covering Structure for Stronger Core Fixation
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Solution Overview
Problem
Existing coil components face issues with the core malfunctioning due to inadequate fixing strength between the core and the exterior body, leading to potential peeling off during use.
Innovation Solution
The coil component incorporates an exterior body with magnetic particles of varying average sizes, where the covering portion has a higher area ratio of smaller particles, enhancing fixation by entering irregularities on the flange portion, and a raised covering portion acts as a stopper to increase the connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core is covered by the exterior body, then the core is protected from malfunction, but the fixing strength between the core and exterior body is insufficient, leading to potential peeling off
Solution Approach 1:
The exterior body is designed with a covering portion that has a different magnetic particle composition compared to the body portion. Specifically, the covering portion contains magnetic particles with a smaller average particle size, creating a local quality difference that enhances fixation strength at the critical interface between the core and exterior body while maintaining overall protection functionality.
Solution Approach 2:
The invention changes the parameter of magnetic particle size in the exterior body material. By using magnetic particles with a smaller average particle size in the covering portion, the material properties are optimized to increase adhesion and fixation strength at the interface where the core meets the exterior body, preventing peeling off while maintaining the protective covering function.
2Ease of manufacture
If magnetic particles of uniform size are used in the exterior body, then the manufacturing process is simple, but the fixation strength at the interface is insufficient
Solution Approach 1:
Instead of using magnetic particles of uniform size throughout the entire exterior body, the invention applies a local quality approach by using magnetic particles with a smaller average particle size specifically in the covering portion that contacts the core. This localized variation in particle size enhances fixation strength at the critical interface while keeping the rest of the exterior body manufacturing relatively simple.
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
This design significantly reduces the likelihood of the core peeling off from the exterior body by increasing the fixing strength, ensuring stable performance.
Implementation Method 1
the magnetic particles of the covering portion easily enter irregularities formed on the outer end surface of the flange portion, and the covering portion is fixed (connected) to the flange portion via the magnetic particles that have entered the irregularities
Data Source
AI summary
An exterior body contains magnetic particles having different average particle sizes and a resin. The exterior body includes a body portion covering at least a core portion and a winding portion, and a covering portion raised with respect to an outer end surface of the flange portion, and overlapping the outer end surface when viewed in an axial direction. In a cross-section of the exterior body, an area ratio of the magnetic particles having a small average particle size is higher in the covering portion than in the body portion.