Coil Component Recessed Core Prevents Wire Tilt
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Solution Overview
Problem
Wire-wound power inductors experience a tilt phenomenon due to lack of support in the intangible space between the core and subsequent turns, leading to increased outer diameter, reduced cut margin, and potential exposure of internal coils during the dicing process, resulting in defects and inefficiencies in both low and high current environments.
Innovation Solution
A coil component design featuring a molded portion with a recessed core portion that supports the innermost turn of the wound coil, preventing tilt and maintaining a stable outer diameter, thereby securing a sufficient cut margin and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If force is applied to control fusion and outer diameter during winding, then adhesion between turns is improved, but the coil tilts toward the core due to lack of support in the intangible space
Solution Approach 1:
The support protrusion is formed in advance on the core before the winding process begins. This preliminary structural preparation provides a reference surface that prevents the coil from tilting during the winding process, allowing force to be applied for fusion control without causing alignment issues.
Solution Approach 2:
The support protrusion acts as an intermediary element between the core and the coil. It mediates the interaction by providing mechanical support to the innermost turn, preventing the coil from tilting toward the core while still allowing the necessary force to be applied for proper fusion and adhesion.
2Strength
If the coil is wound with proper adhesion control, then fusion between turns is improved, but the outer diameter increases beyond design specifications
Solution Approach 1:
The support protrusion is pre-formed on the core to establish a precise starting position for the innermost turn. This preliminary positioning ensures that subsequent turns are wound at the correct radius, maintaining the designed outer diameter while still allowing adequate force to be applied for proper fusion.
3Length of moving object
If the outer diameter is reduced to meet design specifications, then cut margin is improved, but the coil becomes more susceptible to tilt during winding
Solution Approach 1:
The support protrusion is formed in advance on the core to provide a stable reference surface. This preliminary structural preparation enables the coil to be wound with a smaller outer diameter while maintaining proper alignment, as the protrusion prevents tilting even at reduced dimensions.
4Reliability
If the cut margin is increased to prevent coil exposure, then manufacturing yield is improved, but the overall component size increases
Solution Approach 1:
The support protrusion is pre-formed on the core to ensure precise coil positioning and a stable outer diameter. This preliminary action eliminates the need for excessive cut margins, as the coil maintains its designed dimensions without tilting or exposure during the dicing process, thereby preventing defects without increasing component size.
Data Source
AI summary
A coil component includes a molded portion having one surface and the other surface opposing each other, and including a support portion and a core portion which is disposed on the support portion and includes a recess portion, and a wound coil disposed on the one surface of the molded portion, and having an innermost turn, at least one middle turn and an outermost turn, formed outward from a center of the one surface of the molded portion, wherein at least a portion of the innermost turn of the wound coil is disposed in the recess portion and, a maximum width of the recess portion is 30% or less of a width of the core portion, based on one cross-section of the coil component, including an axis of the core portion.