Coil Component Alignment Structure for Stable Magnetic Gap Assembly
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Solution Overview
Problem
Existing coil components face challenges in achieving a stable positional relationship between the top plate and the core, which is crucial for maintaining desired inductance value and DC superimposition characteristics, as described in Japanese Unexamined Patent Application Publication No. 2011-96815, which focuses on forming a magnetic gap but lacks position control mechanisms.
Innovation Solution
The coil component incorporates projections and recesses on the top plate and core flange portions, with guide surfaces guiding the projections into recesses, forming a gap and ensuring precise alignment through abutment portions, thereby stabilizing the positional relationship between the top plate and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic gap is formed between the top plate and the core by positioning the top plate at a predetermined distance from the top surface of the flange portions, then DC superimposition characteristics are improved, but the positional relationship between the top plate and the core becomes unstable during assembly
Solution Approach 1:
A resin adhesive is introduced as an intermediary substance between the top plate and the core flange portions. The adhesive fills the space while maintaining a controlled gap, enabling both stable assembly through adhesion and preservation of the magnetic gap for DC superimposition characteristics. The adhesive acts as a mediator that reconciles the conflicting requirements of positional stability and gap maintenance.
2Reliability
If the top plate is positioned at a predetermined distance from the flange portions to form a magnetic gap, then inductance value and DC superimposition characteristics are improved, but assembly stability and alignment precision are degraded
Solution Approach 1:
The resin adhesive serves as a mediator that simplifies the manufacturing process. Instead of requiring precise mechanical positioning to maintain the gap, the adhesive naturally fills the space while preserving the gap structure, making assembly more stable and easier to manufacture while maintaining the required magnetic characteristics.
Solution Approach 2:
The invention changes the physical state and properties of the bonding medium from rigid mechanical contact to viscous adhesive material. This parameter change allows the system to maintain the gap distance while achieving stable assembly through the adhesive's flow and bonding properties, improving ease of manufacture.
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 allows for stable assembly with a formed gap, enhancing the precision of the coil component's manufacturing process and improving inductance value and DC superimposition characteristics.
Implementation Method 1
At least one of an outer surface of the projection and a wall surface that defines the recess is provided with a guide surface capable of guiding the projection into the recess
Implementation Method 2
The top plate is fixed to the core with an adhesive interposed therebetween
Implementation Method 3
This magnetic gap prevents the occurrence of magnetic saturation, thereby contributing to the improvement of the DC superimposition characteristics
Data Source
AI summary
A coil component includes a core, and projection is on a lower main surface of a top plate and a recess for receiving the projection is in a top surface of a flange portion in the core. The projection has a frustoconical shape, for example, and the cavity formed by the recess has a conical inner peripheral surface. An outer surface of the projection and a wall surface that defines the recess form guide surfaces which guide the projection into the recess and form first and second abutment portions, respectively, that are brought into abutment against each other. The abutment between the first and second abutment portions defines the termination end of the projection inserted into the recess with a gap between the lower main surface of the top plate and the top surface of the flange portion and aligns the top plate relative to the core.