Coil Component Protrusion Bonding for Miniaturization
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Solution Overview
Problem
Existing coil components face challenges in achieving both adequate bonding strength and maintaining inductance when miniaturized, as the reduction in bonding area leads to reduced bonding strength and increased magnetic resistance.
Innovation Solution
The coil component design includes a drum core and a planar core with protrusions on the flange portions, allowing for a larger bonding area and reduced magnetic resistance by positioning the adhesive between the flange and planar cores without direct contact, and stabilizing the magnetic path with strategically placed vertices on the protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil component is miniaturized to increase productivity and reduce size, then the device dimensions are reduced, but the bonding area between flange portion and planar core is reduced leading to reduced bonding strength
Solution Approach 1:
The invention replaces the flat top surface with a curved surface (protrusion) that creates a gap between the flange portion and planar core. This curvature allows adhesive to be distributed across the entire bonding area rather than being concentrated at contact points, maintaining bonding strength in miniaturized components.
Solution Approach 2:
The invention introduces a curved surface protrusion as an intermediary structure between the flange portion and planar core. This protrusion mediates the bonding process by creating optimal adhesive distribution and maintaining appropriate bonding distance, ensuring reliable bonding even when overall component size is reduced.
2Strength
If the flat surface area is increased to improve bonding strength, then the bonding area is increased, but the magnetic path length is increased leading to reduced inductance
Solution Approach 1:
The curved surface protrusion optimizes the magnetic path by creating a controlled gap that prevents direct contact between flange and planar core. This curvature allows the magnetic flux to follow an optimized path through the adhesive layer, reducing magnetic resistance while maintaining adequate bonding strength without requiring increased flat surface area.
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 ensures stable bonding strength and suppresses inductance reduction, allowing for accurate mounting and efficient magnetic path stability even in miniaturized forms.
Implementation Method 1
because a capillary phenomenon can be produced on the central portion side in the vicinity of the flat surface 10 of the top surface 6 in the gap, the space between the flange portion 2 and planar core 3 can be filled with a minimum amount of the adhesive 9
Data Source
AI summary
A coil component includes a drum core including a winding core portion and a flange portion disposed on an end portion thereof the winding core portion in its axial direction, a planar core having a lower principal surface, and a wire wound around the winding core portion. The flange portion includes an inner end surface, an outer end surface, a bottom surface, and a top surface. The inner end surface positions the end portion of the winding core portion. The bottom surface links the inner end surface and the outer end surface and placed so as to face a mounting substrate side when being mounted. The lower principal surface of the planar core is fixed to the top surface with an adhesive interposed therebetween. The top surface includes a protrusion with a vertex positioned closer to the inner end surface than to the outer end surface.