Embedded Coil Terminal Base for Stable Inductance Positioning

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Solution Overview

Problem

Existing coil devices face issues with coil displacement during compression molding, leading to deviations in inductance characteristics and reduced reliability due to the lack of precise positioning of the coil within the element body.

Innovation Solution

The coil device incorporates a terminal with a base portion inside the element body, where the end portion of the coil in the winding axis direction is placed on the base portion, ensuring it is fixed and preventing displacement during compression molding, thereby maintaining precise positioning and stable inductance characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the coil is placed inside the element body without a base portion during compression molding, then the manufacturing process is simpler, but the coil position cannot be determined precisely and inductance characteristics deviate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcoil position precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The base portion is prepared in advance inside the element body before the coil is placed. This preliminary preparation of the base portion provides a predetermined position that guides and supports the coil during compression molding, ensuring precise positioning without complicating the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the coil is compressed during molding, then the element body is formed properly, but the coil displaces from its predetermined position

Engineering Contradiction:

Improveelement body formationVSAvoidcoil position stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The base portion acts as an intermediary between the coil and the compression force during molding. It provides a stable platform that allows the element body to be formed through compression while the coil remains positioned on the base portion, preventing displacement during the compression process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the coil position is not fixed, then the manufacturing process is faster, but inductance characteristics show deviations

Engineering Contradiction:

Improvemanufacturing speedVSAvoidinductance characteristic consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The base portion provides localized support at a specific position inside the element body where the coil needs to be positioned. This localized quality enhancement at the base portion area ensures the coil maintains its predetermined position during manufacturing, guaranteeing consistent inductance characteristics without requiring complex fixation mechanisms throughout the entire device.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12198848B2Coil device

Publication Date: 2025.01.14 TDK CORP

AI summary

A highly reliable coil device is provided. An inductor 1 includes: a core 8; a coil 2 embedded inside the core 8; and terminals 4a and 4b provided with wire connecting portions 42a and 42b, to which lead-out portions 3a and 3b of the coil 2 are connected, the wire connecting portions 42a and 42b being disposed inside the core 8, in which the terminals 4a and 4b are disposed inside the core 8, and the terminals 4a and 4b include base portions 41a and 41b on which a second end portion 2b of the coil 2 in a winding axis direction is provided.