Coil Device Bottom Electrode Magnetic Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of conventional common mode choke coils is inefficient due to the complexity of forming side electrodes, which becomes increasingly difficult as the coil size decreases, leading to low production efficiency.
Innovation Solution
The coil device incorporates a magnetic covering element with conductive pillars extending to the bottom side, allowing electrodes to be easily connected at the bottom, simplifying the manufacturing process and improving efficiency by eliminating the need for complex side electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional side electrode formation process is used, then electrical connection is achieved, but manufacturing complexity increases and production efficiency decreases
Solution Approach 1:
The patent moves the electrode connection interface from the side surface to the bottom surface of the magnetic core. The conductive pillars extend downward from the coil winding to the bottom of the magnetic core, allowing external electrodes to connect at the bottom rather than requiring complex side surface connections. This dimensional shift simplifies the manufacturing process and reduces device complexity.
Solution Approach 2:
The patent introduces conductive pillars as intermediary elements that bridge the coil winding and the external electrodes. These pillars provide a straightforward conduction path through the magnetic core, eliminating the need for complex side electrode formation processes and simplifying the overall manufacturing workflow.
2Volume of moving object
If coil size is reduced, then miniaturization is achieved, but side electrode formation becomes increasingly difficult
Solution Approach 1:
By relocating the connection interface to the bottom surface, the patent enables easier electrode formation in miniaturized coils. The bottom connection approach requires less lateral precision and is more compatible with automated assembly processes, making it suitable for smaller coil dimensions where side electrode formation becomes progressively more difficult.
3Productivity
If conventional manufacturing process is used, then common mode choke coil is produced, but production efficiency is low
Solution Approach 1:
The conductive pillars are integrated into the magnetic core structure during core fabrication, rather than being added as a separate post-processing step. This preliminary integration of the conduction path into the core manufacturing process eliminates additional assembly steps and improves production efficiency.
Solution Approach 2:
The conductive pillars serve as pre-formed intermediaries that simplify the connection process. By having these conduction elements ready within the core structure, the patent eliminates time-consuming side electrode formation operations and accelerates the overall manufacturing cycle.
Data Source
AI summary
A coil device includes a first coil pattern, a second coil pattern, an insulating layer, a magnetic covering element and a number of conductive pillars. The second coil pattern is disposed above the first coil pattern, and is spaced apart from the first coil pattern. The insulating layer covers the first coil pattern and the second coil pattern and defines an opening surrounded by the first coil pattern and the second coil pattern. The magnetic covering element covers the insulating layer and extends into the opening. The conductive pillars are disposed within the magnetic covering element and are exposed from a bottom side of the magnetic covering element. A portion of the conductive pillars are electrically connected to the first coil pattern, and another portion of the conductive pillars are connected to the second coil pattern. The coil device can be easily manufactured.