Coil Component Recess Design for Lead Stability
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Solution Overview
Problem
Existing winding-wire-type coil components face instability due to varying wire specifications, leading to potential wire damage and loosening, which affects the performance of the coil component, especially when the lead portion is positioned far from the brim.
Innovation Solution
A coil component design featuring a recess with a curved concave surface on the element body, where the lead portion passes through, providing a stable connection regardless of its position, and a method of manufacturing involving barrel-polishing to form the recess and wind the conductor around the core, ensuring secure attachment to the outer electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the lead portion is positioned far from the brim to accommodate varying wire specifications, then the coil component can adapt to different wire diameters and inductance requirements, but the wire becomes prone to damage and loosening, destabilizing performance
Solution Approach 1:
The flange portion is divided into an inclined surface and a horizontal surface, creating distinct functional zones. The inclined surface guides the lead portion during winding, while the horizontal surface provides a stable positioning platform, segmenting the support function to simultaneously achieve adaptability and reliability
Solution Approach 2:
The horizontal surface acts as an intermediary structure between the lead portion and the external environment. It provides a dedicated positioning platform that mediates the connection, ensuring stable wire placement regardless of variations in wire specifications or lead portion positions
2Volume of moving object
If the coil component is downsized to meet electronic device size requirements, then the overall dimensions are reduced, but the outer electrode thickness is restricted, limiting material application options
Solution Approach 1:
The flange portion extends horizontally outward from the element body, utilizing the radial dimension rather than increasing axial thickness. This dimensional approach allows sufficient electrode material application area while maintaining compact overall component size, resolving the conflict between downsizing and material application requirements
3Reliability
If a specific lead portion position relative to the inclined plane is required to suppress wire damage, then wire protection is improved, but the configuration becomes ineffective when wire specifications change, requiring precise positioning control
Solution Approach 1:
The horizontal surface serves multiple functions: it positions the lead portion during winding, supports the lead portion after winding, and provides a reference plane for consistent positioning regardless of wire specifications. This multi-functionality eliminates the need for complex positioning control while maintaining wire protection across different wire types
Data Source
AI summary
A coil component includes at least one outer electrode, an element body and a conductor. The element body includes a first surface on which at least a portion of each of the outer electrode(s) is provided, a second surface immediately adjacent to the first surface, a core portion extending from the second surface in axial direction of the core portion, and a recess having a curved concave surface replacing at a portion of a ridge line between the first surface and the second surface. The conductor includes a winding portion that extends around a periphery of the core portion of the element body, a junction portion that is electrically joined to the outer electrode at the first surface, and a lead portion that passes through the recess and connects one end of the winding portion to the junction portion via the recess.