Coil Device Wire Connecting Portion Positioning for Element Body Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing coil devices face issues with insufficient element body density due to protruding wire connecting portions, which obstruct the filling of magnetic material, leading to deteriorated inductance characteristics and potential coil deformation during compression molding.
Innovation Solution
The coil device design positions the wire connecting portions outside the lead portions, allowing for sufficient filling of the element body without high-pressure molding, thereby maintaining the integrity and quality of the coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire connecting portion is disposed inside the lead portion to clamp the lead portion, then the lead portion can be securely fixed, but the element body cannot be sufficiently filled in the space inside the lead portion, resulting in insufficient density and deteriorated inductance characteristics
Solution Approach 1:
The wire connecting portion is repositioned from inside the lead portion to outside the lead portion in the left-right direction. This spatial reconfiguration eliminates the interference with element body filling while preserving the clamping function through proper positioning relative to the lead portion outer surface.
2Manufacturing precision
If high pressure is applied during compression molding to fill the space inside the lead portion, then the element body density can be improved, but the coil may deform, degrading the quality of the coil device
Solution Approach 1:
The wire connecting portion is pre-positioned outside the lead portion before compression molding begins. This preliminary arrangement eliminates the need for high-pressure molding to accommodate internal components, allowing standard pressure molding that preserves coil integrity while achieving sufficient element body density.
3Reliability
If the wire connecting portion protrudes inside the lead portion, then the lead portion can be clamped securely, but it becomes a physical obstacle to filling the element body, reducing inductance characteristics
Solution Approach 1:
The wire connecting portion is extracted from the interior space of the lead portion and repositioned to the exterior. This removal from the critical filling zone eliminates the physical obstacle effect while maintaining the necessary clamping function through external positioning and appropriate connection geometry.
Data Source
AI summary
An inductor 1 includes a coil 2 made of a flat wire, a terminal 4a including a wire connecting portion 42a connected to a lead portion 3a of the coil 2, a terminal 4b including a wire connecting portion 42b connected to a lead portion 3b of the coil 2, and a core 8 that covers the coil 2 together with the wire connecting portion 42a and the wire connecting portion 42b. The wire connecting portion 42a is positioned outside the lead portion 3a that is led out in a front-rear direction of the core 8, along a left-right direction of the core 8. The wire connecting portion 42b is positioned outside the lead portion 3b that is led out in the front-rear direction of the core 8, along the left-right direction of the core 8.