Coil Device Terminal Joint Strength via Dummy Conductor
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Solution Overview
Problem
Existing coil devices have insufficient joint strength between the core body and the terminal electrode, leading to potential peeling issues.
Innovation Solution
A coil device with a conductor wound in a coil shape and a terminal electrode connected to both the lead end and a dummy conductor embedded in the core body, where the dummy conductor's end is exposed and connected to the terminal electrode, enhancing the joint strength and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a terminal electrode is connected only to the lead end of the conductor, then the structure is simple, but the joint strength between the core body and terminal electrode is insufficient
Solution Approach 1:
A dummy conductor is embedded in the core body in advance before the terminal electrode is formed. This dummy conductor serves as a preliminary reinforcement structure that prevents peeling of the terminal electrode from the core body, while not interfering with the electrical function since it is not connected to the terminal electrode
Solution Approach 2:
The reinforcement function is separated into two parts: the lead end of the conductor provides electrical connection, while the dummy conductor provides mechanical reinforcement. This segmentation allows each component to fulfill its specific function without compromising the other
2Reliability
If the lead end is left exposed for connection, then electrical connection is achieved, but the lead end may be deformed or displaced during molding and cutting
Solution Approach 1:
The dummy conductor is positioned to overlap with the lead end in the winding axis direction before the molding and cutting processes. This overlapping arrangement provides cushioning support to the lead end during manufacturing, preventing deformation and positional displacement while maintaining the lead end's electrical connection function
Data Source
AI summary
A coil device includes a conductor and a terminal electrode. The conductor is embedded in a core body and wound in a coil shape. The terminal electrode is formed on an end surface of the core body and connected with a lead end of the conductor. The coil device further includes a dummy conductor embedded in the core body separately from the conductor. An end part of the dummy conductor exposed from the end surface of the core body separately from the lead end is connected with the terminal electrode.