Surface Mount Coil Terminal Layout for Reduced Entangling Pitch
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing surface mount transformer structure requires a minimum pitch between entwined terminals to avoid interference with manufacturing equipment, hindering downsizing efforts.
Innovation Solution
A surface mount coil component design featuring entwined terminals bent in different directions and integrated with mounting terminals, allowing for reduced pitch and compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a minimum pitch of approximately 2 mm is reserved between entwined terminals to achieve required voltage resistance and avoid interference with manufacturing equipment, then reliability and manufacturability are improved, but the component size cannot be reduced
Solution Approach 1:
The entwined terminals are bent in the vertical direction (upward or downward) instead of only in the horizontal plane, utilizing the third dimension to achieve insulation separation. This vertical bending allows the pitch between terminals to be reduced while maintaining sufficient insulation distance through the bent configuration, thereby enabling component downsizing without sacrificing voltage resistance reliability
2Ease of manufacture
If a minimum pitch of approximately 2 mm is reserved between entwined terminals to avoid interference with nozzle of automatic winder, then ease of manufacture is improved, but the component size cannot be reduced
Solution Approach 1:
By bending the entwined terminals vertically, the horizontal projection area of the terminals is reduced, allowing the automatic winder nozzle to pass through without interference even with smaller pitch between terminals. This maintains ease of manufacture while enabling downsizing
3Volume of moving object
If entwined terminals are bent facing to the direction of protrusion from the bobbin, then component size is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The entwined terminals are bent in advance during the manufacturing process before final assembly, allowing precise control of the bending shape and position. This preliminary action ensures that the bent terminals maintain the required insulation distance and proper orientation, reducing the impact on manufacturing precision requirements
Data Source
AI summary
Provided is a surface mount coil component comprising: a winding wire with a lead portion; an insulating bobbin with a winding shaft portion for the winding wire; a plurality of mounting terminals protruding from the bobbin; and a plurality of entangling terminals which are formed from the same member as each of the mounting terminals and which are used to entangle the lead portion of the winding wire. A plurality of adjacent entangling terminals are bent with respect to the direction of protrusion from the bobbin; the lead portion is entangled on the bent portions of the entangling terminals.