Drum-Shaped Coil Component Flange Gripping Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components with drum-shaped cores face challenges in miniaturization due to instability during the winding process, as the chuck's grip on the flange portions can lead to directional errors and inadequate posture, preventing effective miniaturization and stable winding.
Innovation Solution
The coil component design includes flange portions with specific surface features, such as projecting stepped portions and flat surfaces, allowing for a stable grip by the chuck, ensuring the drum-shaped core is held correctly during winding, and featuring terminal electrodes with varying clearances to facilitate progressive stamping and adhesive connection, thereby enabling miniaturization without compromising stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the chuck grips the flange portion during winding, then the drum-shaped core can be held for winding, but directional errors occur and posture becomes unstable
Solution Approach 1:
The flange portion is designed with a specific gripping surface that has different properties from other surfaces. The gripping surface is positioned and shaped to provide stable contact with the chuck, while other surfaces maintain precise dimensional relationships. This local differentiation allows the chuck to grip stably without causing directional errors in the overall component precision.
Solution Approach 2:
The gripping surface is pre-positioned on the flange portion during core formation, establishing the correct orientation and position before the winding operation begins. This preliminary positioning ensures that when the chuck grips the flange, the drum-shaped core is already in the correct posture, preventing directional errors during winding.
2Reliability
If the flange portion size is increased to improve chuck grip stability, then winding stability improves, but the overall component size increases preventing miniaturization
Solution Approach 1:
Instead of increasing the overall flange portion size, a specific gripping surface is created with optimized geometry and position. This localized feature provides sufficient contact area for stable chuck gripping while keeping the rest of the flange portion compact, enabling miniaturization without sacrificing winding stability.
Solution Approach 2:
The gripping surface utilizes the vertical dimension (thickness direction) of the flange portion effectively. By creating a stepped structure or inclined surface that extends in the thickness direction, the gripping contact area is increased without expanding the planar dimensions, thus maintaining compact overall size while improving grip stability.
Data Source
AI summary
A coil component includes a drum-shaped core including a winding core portion and first and second flange portions. A base of a terminal electrode disposed on the first flange portion and a base of an other terminal electrode disposed on the first flange portion are adjacent to each other in the direction in which first and second side surfaces oppose each other, and are along a flat surface of an outer end surface. A clearance between the base of the terminal electrode and the base of the other terminal electrode on a side near a lower surface is larger than that on a side near an upper surface.