Coil Terminal Recess Structure for Stronger Adhesive Bonding
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Solution Overview
Problem
The existing coil components face a challenge in improving the bonding strength of metal terminals to flange portions without causing adhesive protrusion, as simply increasing the adhesive amount does not effectively enhance bonding due to unintended adhesive placement.
Innovation Solution
The coil component design incorporates a recessed bonding portion in the metal terminal, where the area of the recess facing the outer end surface is equal to or larger than the facing surface, allowing for a larger adhesive volume without protrusion, thereby enhancing bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of adhesive is increased to improve bonding strength, then bonding strength improves, but adhesive protrudes to unintended portions
Solution Approach 1:
The bonding portion is designed with a recessed structure that extends in the depth dimension (thickness direction), creating a three-dimensional adhesive accommodation space. This allows the adhesive to be contained within the recess rather than spreading laterally, enabling increased adhesive volume without protrusion. The recess depth provides an additional dimension for adhesive storage, resolving the contradiction between bonding strength and placement precision.
Solution Approach 2:
The bonding portion has non-uniform thickness with a recessed region that has greater thickness than the surrounding areas. This local variation in geometry creates a specific zone optimized for adhesive containment and bonding, while other portions maintain their original dimensions. The localized recess structure allows precise control over adhesive placement and volume without affecting the overall terminal dimensions.
2Reliability
If the adhesive amount is increased, then bonding strength can be improved, but the adhesive protrudes beyond the bonding area
Solution Approach 1:
The bonding portion is segmented into distinct functional zones: a recessed adhesive accommodation region and surrounding non-recessed areas. This segmentation allows the adhesive to be confined to the recessed zone while maintaining clear boundaries with other terminal portions. The segmented structure provides reliable adhesive containment without requiring complex additional components or assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively prevents adhesive protrusion and improves the bonding strength of the metal terminal to the flange portion, ensuring reliable attachment and resistance to rotational forces.
Implementation Method 1
each metal terminal is fixed to the outer end surface of each flange portion with an adhesive
Data Source
AI summary
A coil component includes a drum core including a winding core portion, first and second flange portions, a first metal terminal attached to the first flange portion, and a first wire. The first flange portion is connected to a first end of the winding core portion in a direction along a central axis of the winding core portion. A first connection end of the first wire is joined to the first metal terminal, which has a bonding portion that is fixed to an outer end surface. The bonding portion has a facing surface and a recess that is recessed with respect to the facing surface and accommodates an adhesive. When viewed in a direction along a central axis, an area of a region of the recess facing the outer end surface is equal to or larger than an area of the facing surface.