Integrally Continuous Coil Wiring for Reliable Connection
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Solution Overview
Problem
Existing coil components face disconnection issues due to bonding surfaces between connecting members and conductors, which weaken bonding strength and can lead to disconnection under stress, such as heat application.
Innovation Solution
A coil component design featuring integrally continuous inner and outer wiring without bonding surfaces, where the inner wiring is embedded in a resin-filled cylindrical pipe, and the outer wiring is exposed, reducing disconnection risks and incorporating conductive or ceramic resin to match thermal expansion coefficients and enhance contact performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonding wire is used to connect connecting members and columnar conductors, then electrical connection is achieved, but bonding strength is weakened due to bonding surfaces
Solution Approach 1:
The patent merges the inner wiring and outer wiring into a single integrally continuous wiring structure without bonding surfaces. The wiring extends continuously from inside the coil component to the outside, eliminating the need for separate connecting members and bonding processes, thereby resolving the contradiction between achieving electrical connection and maintaining bonding strength.
2Ease of manufacture
If bonding surfaces are created between connecting members and conductors, then electrical connection is established, but disconnection may occur under stress such as heat application
Solution Approach 1:
The wiring is formed as a single continuous structure that extends from the inner portion to the outer portion of the coil component. This merging of the wiring structure eliminates bonding surfaces entirely, preventing disconnection under thermal or mechanical stress while maintaining manufacturing feasibility through a simplified formation process.
3Device complexity
If multiple separate components (connecting members and columnar conductors) are used, then coil structure is formed, but disconnection risk increases due to bonding surfaces
Solution Approach 1:
The patent simplifies the coil structure by merging the inner wiring and outer wiring into a single integrally continuous wiring. This reduces the number of separate components and bonding interfaces, thereby lowering device complexity while simultaneously improving connection reliability by eliminating bonding surfaces that could lead to disconnection.
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
The design significantly reduces disconnection between inner and outer wiring, maintains manufacturing efficiency, and improves thermal expansion matching and contact performance by using resin or ceramic in the pipe, ensuring reliable operation.
Implementation Method 1
the inner wiring is formed into a substantially cylindrical shape, and resin is embedded in the inner wiring. According to this embodiment, since the resin is embedded in the inner wiring of the substantially cylindrical shape, thermal expansion of the inner wiring can be reduced.
Implementation Method 2
the resin is conductive resin. According to this embodiment, since the resin of the pipe is the conductive resin, it is possible to reduce resistance of the inner wiring.
Implementation Method 3
the pipe contains resin. According to this embodiment, since the pipe contains the resin, characteristics of the pipe and the main body portion, such as coefficients of thermal expansion, can be made the same and close contact performance between the pipe and the main body portion is made preferable.
Data Source
AI summary
A coil component includes a main body portion containing resin and having a hole portion, a coil provided in the main body portion, and a substantially cylindrical pipe arranged inside the hole portion. The coil includes an inner wiring embedded in the pipe and an outer wiring exposed from the main body portion. The inner wiring and the outer wiring are integrally continuous.