Coil Component Terminal Bending via Core Opening
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Solution Overview
Problem
Existing coil components require excessive force to bend flat-shaped terminals, leading to reduced bending accuracy and potential damage to the magnetic core, due to the difficulty in applying uniform force and the risk of fluctuating external dimensions.
Innovation Solution
A coil component design featuring a magnetic core with a cut-out opening portion in the terminal, allowing for accurate bending along the corner between the side and bottom surfaces, with a filling member to stabilize the terminal and reduce the necessary bending force, thereby enhancing accuracy and preventing core damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat-shaped terminal is bent approximately 90 degrees along the corner of the magnetic core, then the terminal can be connected to the coil and protrude from the side surface, but excessive force is required and bending accuracy deteriorates
Solution Approach 1:
The terminal is divided into multiple portions: a first portion buried in the magnetic core, a second portion protruding from the side surface, and a third portion extending toward the bottom surface. The opening portion is formed between the second and third portions, allowing the bending to occur in segments rather than as a single large deformation, thereby reducing the force required and improving bending accuracy.
Solution Approach 2:
The opening portion is specifically formed at the location where the terminal transitions from the second portion to the third portion. This local modification creates a hinge-like structure that concentrates the bending action at a specific point, reducing the overall force required and enabling more precise control over the bending angle and position.
2Ease of manufacture
If excessive force is applied to bend the flat-shaped terminal, then the terminal can be deformed to the required position, but the corner of the magnetic core may be damaged
Solution Approach 1:
By segmenting the terminal into multiple portions with an opening between them, the bending force is distributed and reduced. The opening acts as a stress relief point, preventing the concentration of excessive force that could damage the magnetic core corner while still achieving the necessary terminal deformation.
Solution Approach 2:
The opening portion serves as an intermediary structure between the second and third portions of the terminal. It acts as a hinge or pivot point that facilitates bending with reduced force, mediating between the need for terminal deformation and the need to protect the magnetic core from damage.
3Manufacturing precision
If the terminal is bent without an opening portion, then the structure remains simple, but the external dimensions fluctuate due to bending angle variations
Solution Approach 1:
The terminal structure is segmented into multiple portions with an opening between them. This segmentation creates a more complex structure that provides a defined bending hinge point, which in turn improves external dimensional accuracy by ensuring consistent bending angles despite the increased structural complexity.
Solution Approach 2:
The opening portion replaces the need for complex mechanical bending control systems. By creating a natural hinge point through the opening, the structure itself provides the bending control mechanism, eliminating the need for sophisticated external control while achieving high dimensional accuracy.
Data Source
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AI summary
A coil component including: a magnetic core which is formed by a magnetic material and which has a top surface, a bottom surface facing the top surface and a side surface continuous approximately perpendicularly to the top surface and the bottom surface; a coil which is buried inside the magnetic core and whose end portion protrudes from the side surface of the magnetic core; a flat-shaped terminal which protrudes from the side surface of the magnetic core, is bent toward the bottom surface of the magnetic core and is connected with the end portion of the coil, wherein there is formed an opening portion at a position corresponding to the place which is bent for the flat-shaped terminal from the side surface to the bottom surface of the magnetic core.