Edgewise Coil Magnetic Component With Exposed Flat-Wire Electrodes
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Solution Overview
Problem
Existing electronic components with edgewise coils face challenges in efficiently integrating flat wire windings and magnetic cores, particularly in ensuring secure electrode connections and preventing short circuits during manufacturing and mounting processes.
Innovation Solution
The design incorporates a magnetic core with a flat base and an edgewise coil winding, where non-wound flat wires extend along the core's surfaces, serving as electrodes, and are integrated with a magnetic exterior body formed by compression molding with a resin, ensuring secure connections and preventing short circuits through strategic bending and adhesive fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate electrode terminals are used for edgewise coil, then surface mounting is enabled, but device complexity increases
Solution Approach 1:
The patent merges the electrode terminals with the magnetic core by forming the terminals as integral parts of the core structure. The core is formed with protruding portions that serve as electrode terminals, eliminating the need for separate terminal components while maintaining surface mounting capability.
Solution Approach 2:
The magnetic core is designed to serve multiple functions simultaneously: it provides magnetic flux path, structural support, and electrical connection terminals. The protruding portions of the core function both as structural extensions and as electrode terminals for electrical connections.
2Shape
If flat wire is wound vertically with shorter sides at inner and outer circumferences, then edgewise coil structure is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates guide grooves in the magnetic core before the winding process. These guide grooves pre-position the flat wire during winding, ensuring that the shorter sides of the flat wire are correctly oriented at the inner and outer circumferences of the coil, thereby reducing manufacturing precision requirements.
Solution Approach 2:
The guide grooves act as an intermediary structure that facilitates correct wire placement during winding. The grooves physically guide the flat wire into the proper orientation and position, serving as a mediator between the winding process and the final edgewise coil structure.
3Reliability
If non-wound flat wires extend along all surfaces of flat base, then electrode connectivity is improved, but risk of short circuit increases
Solution Approach 1:
The patent segments the extended flat wires into distinct functional zones: winding portions for coil formation and non-wound portions for electrode connections. The non-wound portions are specifically positioned and isolated to serve as electrodes while preventing unintended electrical connections.
Solution Approach 2:
Different portions of the flat wire are assigned different functions and properties. The winding portions are insulated and wound into coils, while the non-wound portions extending along the surfaces are configured as exposed electrodes. The magnetic core structure provides localized guidance and positioning to ensure proper spatial separation and prevent short circuits.
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 allows for easy bending and secure mounting of non-wound wires, enhancing productivity and preventing short circuits, while maintaining excellent insulation characteristics and ensuring the electronic component's stability during manufacturing and usage.
Implementation Method 1
a magnetic exterior body that covers at least the core and the edgewise coil
Implementation Method 2
the two non-wound wires may be connected to the bottom surface of the flat base with an adhesive
Data Source
AI summary
An electronic component comprises: a magnetic core having a flat base and a core, the flat base having a top, a bottom, and first and second opposite sides, the core is on the top; a winding having an edgewise coil including a wound flat wire and the core, the winding having two non-wound flat wires extending therefrom; and a magnetic exterior body covering the core and the edgewise coil. The two non-wound flat wires extend along the top, the first side, the bottom and then the second side, and the two non-wound flat wires are non-adhesively positioned around the flat base. The two non-wound flat wires on the bottom are externally exposed electrodes. The second side inclines towards the core. The two ends of the two non-wound flat wires are embedded into the magnetic exterior body to fix the two non-wound flat wires to the magnetic exterior body.