Coil Component Lead Layout to Prevent Winding Loosening
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Solution Overview
Problem
Existing coil components face challenges in maintaining a compact installation space while allowing large current flow, as structures with lead parts connected to external electrodes on a single face tend to experience loosening of the winding due to wire elasticity, leading to a drop in inductance, especially with rectangular wires and alpha-winding configurations.
Innovation Solution
A coil component design featuring a drum core with a winding shaft and flange parts, where lead parts are bent towards one flange part and connected to external electrodes formed by sputtering or plating, with an exterior resin covering the coil and lead parts to secure them in place, ensuring the shortest distance between the flange side face and the winding part is less than or equal to the wire thickness, preventing loosening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If lead parts are bent toward one flange part and connected to external electrodes on a single face to reduce installation space, then the installation space is reduced, but the winding loosens due to wire elasticity causing inductance drop
Solution Approach 1:
The patent applies preliminary action by forming the exterior resin to cover and secure the lead parts before final assembly completion. The resin is applied in advance to prevent winding loosening that would occur during subsequent handling and installation, addressing the reliability issue before it manifests.
Solution Approach 2:
The exterior resin acts as an intermediary substance between the lead parts and the external environment. It mediates the conflict between bending the lead parts for compact installation and maintaining winding stability by providing mechanical support and constraint through the resin coating.
2Power
If conductive wire of large cross-section area is used to allow large current flow, then current carrying capacity is improved, but the circuit opens at wire-external electrode junctions due to wire elasticity
Solution Approach 1:
The exterior resin serves as an intermediary that secures the connection between large cross-section conductive wires and external electrodes. It provides mechanical support that counteracts wire elasticity, preventing circuit opening while maintaining the high current carrying capacity enabled by the larger wire cross-section.
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connection interface by introducing the exterior resin. This parameter change transforms the connection from a mechanically vulnerable joint to a stabilized assembly that can accommodate large wire cross-sections without opening.
3Ease of manufacture
If alpha-winding structure is used to reduce bending force, then manufacturing is simplified, but the end of winding becomes particularly vulnerable to loosening
Solution Approach 1:
The exterior resin acts as an intermediary that compensates for the reduced mechanical constraint in alpha-winding structures. It provides the necessary support to prevent loosening at the vulnerable end of winding while maintaining the manufacturing simplicity and low bending force characteristics of the alpha-winding method.
Solution Approach 2:
The patent applies beforehand cushioning by pre-coating the lead parts and winding with exterior resin before assembly is completed. This creates a protective cushion that prevents loosening of the alpha-winding structure during subsequent handling and installation, maintaining winding tightness without compromising manufacturing ease.
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 effectively prevents the loosening of the winding in the coil, thereby maintaining inductance and allowing for the use of thicker conductive wires or alpha-winding structures without a significant drop in inductance, while also enabling high-density mounting on circuit boards.
Implementation Method 1
the elasticity of the conductive wire may cause the winding of the coil in the winding part to loosen when bending is performed
Implementation Method 2
external electrodes are instead formed by means of sputtering, plating, etc., at the ends of the conductive wire
Implementation Method 3
external electrodes are instead formed by means of sputtering, plating, etc., at the ends of the conductive wire
Data Source
AI summary
In an exemplary embodiment, a coil component includes: a drum core 10 that includes a winding shaft 12 and flange parts 14a, 14b; a coil 40 that includes a winding part 42 and a pair of lead parts 44a, 44b led out from the winding part 42 toward a side face 22 of the flange part 14a and then bent onto the flange part 14a along the side face 22; and a pair of external electrodes 60a, 60b provided on the outer face 17a of the flange part 14a, and connected to the pair of lead parts 44a, 44b; wherein the shortest distance L4 between the side face 22 and the outermost periphery of the winding part 42 is shorter than the shortest distance L3 between a side face 24, opposite the side face 22, of the flange part 14a, and the outermost periphery of the winding part 42.