Coil Terminal Fitting Structure for Reduced DC Resistance
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Solution Overview
Problem
Conventional winding-type coil devices experience increased DC resistance due to the separation of metal terminal mounting surfaces and wire connection points, making them less suitable for power supply applications.
Innovation Solution
A coil device design featuring a winding core with a flange, a wire wound around it, and a terminal fitting with a protrusion plate that brings the wire connection surface and main mounting surface close together, reducing DC resistance by minimizing the distance between these points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal terminals are attached to flanges with wire connection points separated from mounting surfaces, then the coil device can be manufactured with conventional structures, but DC resistance increases
Solution Approach 1:
The patent merges the mounting surface and wire connection point into a single integrated terminal fitting structure. The terminal fitting includes a contact part that contacts the flange and a protrusion plate part that provides both the wire connection surface and main mounting surface, eliminating the separation between these functions and reducing DC resistance.
Solution Approach 2:
The patent extends the terminal fitting in the perpendicular direction from the flange surface by creating a protrusion plate. This dimensional extension allows the wire connection surface and main mounting surface to be positioned close to each other while maintaining proper electrical and mechanical connections, thereby reducing DC resistance without compromising manufacturing ease.
2Loss of energy
If wire connection surface and main mounting surface are positioned close together, then DC resistance is reduced, but terminal fitting structure becomes more complex
Solution Approach 1:
The terminal fitting integrates multiple functions into a single component: electrical contact with the flange, wire connection, and circuit board mounting. By combining these functions in one protrusion plate structure, the patent achieves close positioning of surfaces without requiring multiple separate components, thus limiting the increase in overall device complexity.
Solution Approach 2:
The terminal fitting serves multiple purposes simultaneously: it provides electrical contact with the flange through the contact part, offers a wire connection surface on the protrusion plate, and provides a main mounting surface for circuit board attachment. This multi-functionality reduces the need for additional components while achieving low DC resistance.
Data Source
AI summary
A coil device includes a winding core, a wire, and a terminal fitting. The winding core is made of a magnetic material and includes a flange. The wire is wound around the winding core. The terminal fitting is attached to a part of an outer surface of the flange. The terminal fitting includes a contact part and a protrusion plate part. The contact part is contacted with the outer surface of the flange. The protrusion plate part is formed integrally with the contact part and protrudes away from the flange. The protrusion plate part includes a wire connection surface and a main mounting surface. A lead end of the wire is connected to the wire connection surface. The main mounting surface is located opposite to the wire connection surface and is connectable to an external circuit.