Coil Component Wire Fixing via Drum Core Convex Feature
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Solution Overview
Problem
In coil components with wire fixing portions, it is difficult to sufficiently bend and securely fix the wire due to gaps between the wire fixing portion and the drum core, leading to inadequate fixation.
Innovation Solution
A coil component design with a drum core and metal terminals where the shortest distance from the flange portion's side surface to the wire fixing portion is smaller than to the wire connecting portion, and a convex portion on the flange surface reduces the gap, allowing for efficient bending and secure fixation of the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire fixing portion is positioned at a standard distance from the flange portion, then the metal terminal structure is simple, but the wire fixing portion cannot be sufficiently bent and the wire fixation is insecure
Solution Approach 1:
The patent applies local quality by creating a convex portion at a specific location on the flange portion. This localized structural modification provides a reference surface that enables sufficient bending of the wire fixing portion without complicating the overall metal terminal structure. The convex portion is strategically positioned to affect only the local bending behavior where wire fixation is needed, while leaving the rest of the structure simple.
2Reliability
If a convex portion is added to the flange portion to reduce the gap, then the wire can be more securely fixed, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the convex portion with the flange portion to form an integrated structure. The convex portion is not a separate component but is formed as part of the flange portion itself, allowing it to be manufactured in one piece with the flange. This integration reduces the number of parts and assembly steps, thereby simplifying the manufacturing process while still providing the gap-reducing function for secure wire fixation.
3Manufacturing precision
If the wire fixing portion is positioned closer to the flange portion side surface, then the gap is reduced and bending is sufficient, but the wire connecting portion positioning becomes more constrained
Solution Approach 1:
The patent resolves the positioning conflict by utilizing the convex portion as a spatial reference feature. The convex portion protrudes from the flange portion surface, creating a three-dimensional reference point that enables precise positioning of the wire fixing portion relative to the flange. This dimensional approach allows the wire fixing portion to be positioned close to the flange side surface for sufficient bending, while the wire connecting portion can be positioned appropriately in another direction without interference.
Data Source
AI summary
In a coil component, a shortest distance from a longitudinal wall of a flange portion of a drum core to a wire fixing portion is smaller than a shortest distance of the longitudinal wall to an electrode wire connecting portion by a convex portion formed at the longitudinal wall of the flange portion. That is, since a gap between the flange portion of the drum core and the wire fixing portion is small (or there is no gap), the wire fixing portion can be sufficiently bent. Accordingly, the wire can be securely fixed by a wire fixing portion of a metal terminal.