Coil Winding Structure With Side-Surface Wire Intersection
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Solution Overview
Problem
As the size of coil components decreases, the thickness of the core and flange portions also decreases, leading to smaller terminal electrodes and a reduced space for wire connections. This results in stress concentration at bent wire portions, potentially degrading the quality of wire-terminal connections.
Innovation Solution
A coil component design featuring a core with a winding core portion and flange portions, where the wires are wound in the same direction and intersect along the side surface of the core near the flange portions. This design allows the wires to be gently bent towards the flange portions, reducing stress concentration and maintaining connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the coil component is decreased, then the miniaturization of the component is achieved, but the space for wire connections is reduced and stress concentration occurs at bent wire portions
Solution Approach 1:
The patent positions the intersecting portion of the wires at the side surface of the winding core portion rather than at the end surface near the flange portion. This spatial repositioning in a different dimension provides adequate space for wire bending and connection while maintaining the miniaturized component size, thereby preventing stress concentration and connection quality degradation.
2Length of stationary object
If the thickness of the winding core portion and flange portions is decreased, then the component size is reduced, but the areas of the terminal electrodes decrease and wire connection space is limited
Solution Approach 1:
By relocating the wire intersecting portion to the side surface of the winding core portion, the patent creates additional connection space in a different dimensional orientation. This allows the terminal electrodes to maintain adequate area for wire connections even when the overall component thickness is reduced, thus resolving the contradiction between component miniaturization and connection quality.
Data Source
AI summary
A coil component includes a core including a winding core portion, a first flange portion, and a second flange portion, and a first wire and a second wire that are wound around the winding core portion in the same direction and that form a winding portion. The winding portion includes a second intersecting portion along a third side surface of the winding core portion at a position on the winding portion nearest to the second flange portion.