Coil Component Flange Structure for Adhesive Containment

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Solution Overview

Problem

As the size of coil components decreases, the thickness of the core and flange portions also decreases, leading to a reduced area where the plate member and flange portions face each other, causing adhesive to protrude outside due to variations in adhesive application, and affecting the magnetic circuit length and inductance value.

Innovation Solution

A coil component design with a core, flange portions, and a plate member where the plate member is mounted with adhesive, featuring recessed portions on the flange portions to direct the adhesive into increasing distance regions, preventing protrusion and stabilizing the magnetic circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the size of the coil component is decreased, then the miniaturization is achieved, but the area where the plate member and flange portions face each other is reduced, causing adhesive to protrude outside

Engineering Contradiction:

Improvesize of coil componentVSAvoidadhesive positioning accuracy

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The flange portion is divided into a first flange portion and a second flange portion that are positioned at different locations. The plate member is secured to both flange portions with adhesive, creating separate bonding areas. This segmentation prevents adhesive from protruding to the outside by distributing the adhesive in controlled regions between the plate member and each flange portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second flange portion acts as an intermediary structure between the plate member and the first flange portion. By positioning the plate member on both flange portions with adhesive, the second flange portion helps contain the adhesive within specific regions, preventing it from protruding outward while maintaining the electrical connection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the thickness of the winding core portion and flange portions is decreased, then the miniaturization is achieved, but the adhesive is highly likely to protrude due to variation in adhesive application

Engineering Contradiction:

Improvethickness of core and flange portionsVSAvoidadhesive containment reliability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The flange portion is segmented into a first flange portion and a second flange portion positioned at different locations. The plate member is secured to both segments with adhesive, creating multiple controlled bonding areas. This segmentation ensures that even with thin dimensions, the adhesive remains contained within specific regions between the plate member and each flange portion, preventing protrusion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the spatial parameter by positioning the second flange portion at a different location than the first flange portion. This parameter change creates distinct adhesive bonding regions that are less susceptible to variation in adhesive application, thereby maintaining reliable adhesive containment even when the overall component thickness is reduced.

Inventive Principle:

Principle #35Parameter changes

3Area of stationary object

If the area where plate member and flange portions face each other is reduced, then the miniaturization is achieved, but the adhesive protrusion increases affecting the magnetic circuit

Engineering Contradiction:

Improvefacing area between plate member and flange portionsVSAvoidadhesive protrusion affecting magnetic circuit

Core Design Contradiction:

Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The flange portion is segmented into a first flange portion and a second flange portion positioned at different locations. The plate member is secured to both segments with adhesive, creating separate and controlled bonding areas. This segmentation prevents adhesive from protruding to the outside by distributing the adhesive in controlled regions between the plate member and each flange portion, thereby eliminating the harmful effect on the magnetic circuit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention converts the potential harm of adhesive protrusion into a beneficial controlled bonding structure. By using the adhesive to bond the plate member to both the first and second flange portions at different locations, the adhesive is contained within specific regions and actually contributes to the structural integrity and electrical connection, rather than protruding and interfering with the magnetic circuit.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS12165799B2Coil component

Publication Date: 2024.12.10 MURATA MFG CO LTD

AI summary

A coil component includes a core including a winding core portion, a first flange portion, and a second flange portion, and a plate member that is mounted on the first flange portion and the second flange portion. A distance in a height direction between the plate member and the first flange portion, or a distance in the height direction between the plate member and the second flange portion, or both vary in a length direction, or in a width direction, or both.