Coil Component Flange Ridges for Reliable Solder Fillets
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Solution Overview
Problem
Existing coil components with flat outer flange portions complicate the formation of terminal electrodes, which is necessary for forming solder fillets and enhancing reliability, especially in applications like vehicles.
Innovation Solution
A coil component design featuring flange portions with ridges and grooves on both the outer and mount surfaces, allowing for easy formation of terminal electrodes on the ridges, which facilitates the creation of solder fillets when mounted on a printed circuit board, thereby improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal electrodes are formed on the outer side of a flat flange portion, then solder fillets can be formed to improve reliability, but the manufacturing process becomes complicated
Solution Approach 1:
The outer side surface of the flange portion is segmented into multiple ridges separated by grooves. This segmentation allows terminal electrodes to be formed only on the ridges, creating natural isolation zones that simplify the electrode formation process while enabling solder fillet formation for improved reliability.
Solution Approach 2:
Instead of making the entire flange surface suitable for terminal electrode formation, the invention applies terminal electrodes locally only on the ridges. The grooves between ridges remain free of electrodes, creating distinct functional zones that simplify manufacturing while achieving the reliability benefit of solder fillets.
2Reliability
If terminal electrodes are formed on the flange portion to enable solder fillet formation, then mounting reliability improves, but the process complexity increases
Solution Approach 1:
The flange portion is structurally segmented into ridges and grooves, where terminal electrodes are formed only on the ridges. This segmentation simplifies the overall device structure by providing built-in isolation features, reducing the need for additional isolation components or complex electrode patterns.
Solution Approach 2:
The ridges and grooves are pre-formed on the flange portion before terminal electrode formation. This preliminary structural preparation simplifies the subsequent electrode formation process, as the ridges naturally define where electrodes should be placed and the grooves automatically provide isolation.
3Ease of manufacture
If the flange portion outer side is kept flat for simple structure, then manufacturing is easier, but terminal electrode formation and solder fillet creation become difficult
Solution Approach 1:
The flat outer side surface is replaced with a curved or raised ridge structure. The ridges protrude from the flange surface, creating three-dimensional features that are easier to manufacture with standard molding processes while providing excellent surfaces for terminal electrode formation and solder fillet creation.
4Reliability
If ridges and grooves are added to the flange portion to facilitate terminal electrode formation, then solder fillet formation improves, but the structural complexity increases
Solution Approach 1:
The ridges serve multiple functions simultaneously: they provide structural support for the drum core, create natural isolation zones through grooves, and offer optimized surfaces for terminal electrode formation. This multi-functionality reduces the need for separate features, simplifying the overall structure despite the added ridge-groove pattern.
Data Source
AI summary
Disclosed herein is a coil component that includes a drum core including a pair of flange portions and a winding core portion positioned between the flange portions, a plurality of terminal electrodes formed on the flange portions, and a plurality of wires wound around the winding core portion, each end of the wires being electrically connected to an associated one of the terminal electrodes. Each of the flange portions has an inner side surface connected to the winding core portion and an outer side surface opposite to the inner side surface, the outer side surface has a plurality of ridges and at least one groove, and the terminal electrodes are formed on at least the ridges of the outer side surfaces such that the terminal electrodes are isolated from each other by the groove.