Coil Component Flange Design for Magnetic Efficiency
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Solution Overview
Problem
Existing coil components with drum-shaped cores and flange portions suffer from low magnetic efficiency due to large magnetic resistance gaps, limiting inductance and high frequency characteristics, particularly in applications requiring higher inductance without increasing the winding number of wires.
Innovation Solution
The coil component design enhances the contact area between flange portions and a plate-shaped core, ensuring a larger contact area of ⅔ or more of the product of the maximum width and length, which decreases magnetic resistance and allows for increased inductance without additional windings, using an adhesive to secure the flange portions to the plate-shaped core and optimizing terminal electrode placement for reduced deformation and improved flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding number of wire is increased to compensate for low magnetic efficiency, then the inductance can be maintained, but the interline capacitance and resistance loss increase, degrading high frequency characteristics
Solution Approach 1:
The patent converts the harmful effect of gap magnetic resistance into a benefit by precisely controlling and minimizing the gap area between flange portions and plate-shaped core. By making the gap area 1/3 or less of the flange top surface area, the magnetic resistance is reduced to acceptable levels, allowing the use of fewer wire turns while maintaining inductance and improving high frequency characteristics.
2Area of stationary object
If the flange portions are made shorter to reduce external dimensions for mounting, then the mounting area is reduced, but the contact area with plate-shaped core decreases, increasing magnetic resistance
Solution Approach 1:
The patent changes the critical parameter of gap area between flange portions and plate-shaped core by optimizing the contact area ratio. By requiring the contact area to be 1/3 or less of the flange top surface area, the design achieves low magnetic resistance without constraining the overall external dimensions or mounting area, thus resolving the contradiction between compact mounting and magnetic efficiency.
3Reliability
If the contact area between flange portions and plate-shaped core is increased, then the magnetic resistance decreases and inductance increases, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies partial action by setting the contact area ratio at 1/3 or less of the flange top surface area, which is sufficient to achieve low magnetic resistance without requiring excessive precision. This partial contact area optimization provides a practical balance between magnetic efficiency and manufacturability, avoiding the need for extremely precise manufacturing while still achieving the desired magnetic performance.
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 configuration significantly reduces magnetic resistance, enabling higher inductance and improved high-frequency characteristics without increasing the winding number of wires, thus enhancing the coil component's performance in high-frequency applications like 10GBASE-T standards.
Implementation Method 1
using an adhesive to secure the flange portions to the plate-shaped core
Implementation Method 2
the sum of the areas of contact portions which are included in the top surfaces of the first and second flange portions and which contact the one principal surface of the plate-shaped core is 1/3 or smaller... magnetic resistance generated by a gap unavoidably formed between the top surfaces of the flange portions and the one principal surface of the plate-shaped core is relatively large
Data Source
AI summary
The sum of the area of a region occupied by a top surface of a first flange portion and the area of a region occupied by a top surface of a second flange portion is ⅔ or larger the area of an imaginary quadrangle defined by two vertices on the side of the outer periphery of the top surface of the first flange portion, and two vertices on the side of the outer periphery of the top surface of the second flange portion.