Coil Terminal Structure to Prevent Wire-Substrate Interference
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Solution Overview
Problem
Existing coil components face issues with wire end portions interfering with substrates due to complex shapes or protruding parts, leading to potential breakage and reduced volume.
Innovation Solution
A coil component design with terminal fittings having wire connecting parts and mounting parts that overlap the flange surfaces, allowing for a gap and springiness to prevent interference and stress relaxation, maintaining a simple shape and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal fitting has a wire connecting part that covers the mounting surface of the flange part, then the wire can be connected to the terminal fitting, but the end portion of the wire interferes with the substrate when the coil component is mounted
Solution Approach 1:
The patent introduces a stepped structure with different height levels (first height and second height) in the flange part. The wire connecting part is positioned at a higher level while the mounting surface is at a lower level, creating vertical separation that prevents wire interference with the substrate while maintaining wire connection functionality
Solution Approach 2:
The flange part is segmented into multiple regions with different heights: a first flange region for wire connection, a second flange region for mounting, and a stepped transition region. This segmentation allows each region to perform its specific function independently without interference
2Object-affected harmful factors
If a step is formed in the flange part to prevent interference between the wire end portion and the substrate, then wire interference is prevented, but the shape of the drum core becomes complicated and the volume of the drum core is reduced
Solution Approach 1:
Instead of adding complex lateral protrusions or multi-directional steps, the patent uses a simple axial stepped structure along the winding axis. The first and second flange parts are positioned at different axial locations with different heights, creating interference prevention in the vertical dimension while keeping the overall drum core shape simple and maintaining volume
3Object-affected harmful factors
If the mounting part of the terminal fitting is separated upward from the flange part to prevent interference, then wire interference is prevented, but the wire connecting part protrudes outward increasing the mounting area and making it more susceptible to external forces
Solution Approach 1:
The patent positions the wire connecting part in the vertical dimension (axial direction) by creating a first flange part that extends higher than the second flange part, rather than protruding outward in the radial direction. This vertical separation prevents wire interference while keeping the wire connecting part within the overall footprint of the drum core, reducing mounting area and protecting against external forces
4Object-affected harmful factors
If the wire connecting part protrudes outward in the width direction to separate the mounting part from the flange part, then wire interference is prevented, but the mounting area is increased
Solution Approach 1:
The patent prevents wire interference by creating vertical height differences in the axial direction rather than increasing radial protrusions. The first flange part with wire connecting part is positioned at a higher axial level, while the second flange part for mounting remains at a lower level, maintaining a compact radial footprint and minimizing mounting area
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
Prevents wire-substrate interference without complicating the core shape, enhances mounting reliability, and reduces the risk of breakage by relaxing stress through springiness.
Implementation Method 1
The mounting part has springiness with respect to the drum core... the stress is relaxed by the mounting part having springiness
Implementation Method 2
stress is applied to the solder due to a difference in thermal expansion coefficient between the drum core and the substrate
Data Source
AI summary
Disclosed herein is a coil component that includes a drum core; a terminal fitting fixed respectively to the flange part of the drum core; and a wire wound around the winding core part of the drum core. The terminal fitting has a wire connecting part to which the wire is connected and a mounting part having springiness with respect to the drum core. The distance between the flange part and the mounting part is larger than the distance between the flange part and the wire connecting part.