Coil Core Flange Ridges for Stable Chucking During Winding
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Solution Overview
Problem
The downsizing of coil components leads to a reduced dimension between the outer and inner end surfaces of the flange portion, making it difficult to hold the core in a stable posture during the winding process, resulting in axis deviation and improper rotation.
Innovation Solution
Incorporating first and second ridges on the outer end surfaces of the flange portions, which increase the contact area with the chuck, allowing for stable core positioning and rotation during winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the dimension between outer end surface and inner end surface of the flange portion is reduced for downsizing, then the size of the coil component is decreased, but the contact area with the chuck is reduced making it difficult to hold the core in a stable posture
Solution Approach 1:
The patent applies local quality by adding ridges to specific locations on the flange portion's outer end surface. These ridges concentrate the contact area with the chuck at particular points, increasing local contact pressure and friction without increasing the overall flange dimension. This allows stable core holding while maintaining the downsized configuration.
2Quantity of substance
If the thickness of the flange portion is decreased to increase windings without increasing size, then the number of windings is increased, but the contact area with the chuck is further reduced worsening the holding stability
Solution Approach 1:
The patent addresses this contradiction by transitioning from a two-dimensional contact surface to a three-dimensional ridge structure. The ridges extend in the radial direction, creating additional contact surfaces and points that engage with the chuck. This dimensional change allows the flange to maintain reduced thickness while providing sufficient contact area for stable core holding during the winding process.
Data Source
AI summary
A coil component capable of holding a core in a stable posture by a chuck in a winding step of a wire. The core includes a winding core portion extending in an axial direction, and a first flange portion and a second flange portion provided at end portions of the winding core portion opposite to each other in the axial direction. Each of outer end surfaces of the first flange portion and the second flange portion has a first ridge extending along a ridgeline where the outer end surfaces intersect first side surfaces and a second ridge extending along a ridgeline where the outer end surfaces intersect second side surfaces.