Coil Magnetic Plate Structure to Prevent Cracks and Chips
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Solution Overview
Problem
The quality of known coil components degrades due to cracks and chips in the magnetic plate's storage portion, which affects the overall performance of the coil.
Innovation Solution
A coil component design featuring a magnetic plate with an annular first planar portion, a second planar portion with a step, and a connection surface portion comprising at least three inclined slopes with chamfered portions between them, which reduces the occurrence of cracks and chips during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a magnetic plate with a concave storage portion is used, then adhesive can be stored for bonding, but cracks and chips are likely to be generated in the storage portion
Solution Approach 1:
The connection surface portion is designed with curved surfaces instead of sharp corners. The first connection surface has a first curvature radius, and the second connection surface has a second curvature radius, both greater than zero. This curvature design eliminates stress concentration points that would otherwise cause cracks and chips, while still providing a surface for adhesive bonding.
Solution Approach 2:
The invention changes the geometric parameters of the connection surfaces by specifying curvature radii. The first curvature radius is set to be larger than the second curvature radius, creating a gradual transition that reduces stress concentration. This parameter optimization allows the structure to maintain both manufacturability and reliability.
2Ease of manufacture
If a magnetic plate with sharp corners is used, then manufacturing is simpler, but defects like cracks and chips occur more frequently
Solution Approach 1:
Instead of using sharp corners in the magnetic plate design, the invention applies curved surfaces with specific curvature radii at the connection portions. This eliminates the stress concentration that occurs at sharp corners during molding and handling, significantly reducing the defect rate while maintaining manufacturing feasibility.
3Ease of manufacture
If the connection surface is perpendicular to the first planar portion, then manufacturing is easier, but mold filling and removal become difficult
Solution Approach 1:
The connection surfaces are designed with curved geometries rather than perpendicular flat surfaces. The first and second connection surfaces have curvature radii that facilitate material flow during molding, enabling complete mold filling and easy removal of the magnetic plate from the mold while maintaining manufacturing simplicity.
Data Source
AI summary
A coil component includes a core including a winding core portion and a pair of flange portions provided at both ends of the winding core portion, electrode portions provided in the flange portions, a wire wound around the winding core portion, and a magnetic plate fixed to the flange portions. The magnetic plate includes an annular first planar portion, a second planar portion that is located inside the inner circumference of the first planar portion and has a step between the first and the second planar portions, and a connection surface portion connecting the inner circumference of the first planar portion to the outer circumference of the second planar portion. The connection surface portion is configured by annularly disposing at least three slopes inclined with respect to the direction orthogonal to the first planar portion and has chamfered portions each being disposed between adjacent slopes.