Coil electronic comonent
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Solution Overview
Problem
Existing power inductors, particularly wire-wound types, face challenges in maximizing capacity versus volume and are prone to short circuits due to large gaps between the coil end surface and the main body, which can lead to mounting issues on substrates.
Innovation Solution
A coil electronic component design featuring a main body with a wound coil embedded within, where the distance between the coil end surface and the outermost turn is optimized between 2% to 7.5% of the main body's length, and lead terminals are positioned to reduce exposure and increase the thickness of the lower cover layer, thereby embedding parts of the terminals inside the main body to minimize short circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the gap between the end surface of the main body and the coil is reduced to increase capacity versus volume, then the inductor capacity increases, but the risk of short circuit during mounting increases
Solution Approach 1:
The patent positions the external electrodes on the lower surface of the main body rather than on the longitudinal end, changing the spatial dimension of electrode placement. This dimensional change allows the coil to be positioned closer to the end surface (reducing gap distance and increasing capacity) while the electrodes remain protected on the lower surface, preventing short circuit risks during mounting.
Solution Approach 2:
The patent applies different structural characteristics to different parts of the inductor. The upper part features a reduced gap between the end surface and coil for maximum capacity, while the lower surface maintains exposed external electrodes for safe mounting. This local differentiation resolves the contradiction by optimizing each region for its specific function.
2Ease of operation
If the external electrodes are exposed to the longitudinal end of the main body for easy mounting, then the ease of operation improves, but the risk of short circuit occurrence increases
Solution Approach 1:
The patent designates specific regions for different functions: the lower surface of the main body houses the external electrodes for mounting operations, while the longitudinal end surface maintains a reduced gap for capacity optimization. This localized functional assignment allows easy mounting through the lower surface electrodes without exposing them to the longitudinal end, thereby eliminating short circuit risks.
Solution Approach 2:
The external electrodes are relocated from the longitudinal end (one-dimensional exposure) to the lower surface (different spatial dimension). This dimensional relocation maintains mounting accessibility while removing the electrodes from the high-risk longitudinal end region, solving the contradiction between ease of operation and short circuit prevention.
3Quantity of substance
If the distance between the end surface and the outermost turn coil is optimized to 2%-7.5% of the main body length, then the capacity versus volume increases, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies an optimized parameter range for the distance between the end surface and the outermost turn coil (2%-7.5% of the main body length L1). By defining this specific parameter range, the patent achieves improved capacity versus volume while establishing clear manufacturing tolerances that balance precision requirements with practical manufacturability.
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 design enhances capacity versus volume and reduces the risk of short circuits during mounting on a circuit board by optimizing the coil placement and terminal positioning, ensuring efficient power management and reliability.
Implementation Method 1
a wound coil of which at least a part is embedded in the main body
Implementation Method 2
a main body including a magnetic material
Data Source
AI summary
A coil electronic component includes a main body including a magnetic material, a wound coil of which at least a part is embedded in the main body, and a first and second lead terminals connected to both end portions of the wound coil, respectively, where in a cross-section perpendicular to a width direction of the main body, a first distance D1, which is a distance between an end surface of the main body in a length direction and an outermost turn coil of the wound coil, measured along the length direction of the main body at a half point of a thickness T1 of the main body, is greater than or equal to 2% and smaller than or equal to 7.5% of a length L1 of the main body in the length direction.