Grooved Flange Coil Component for Impact-Resistant Terminals
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Solution Overview
Problem
Existing coil components are prone to damage and terminal separation when subjected to impact due to concentrated force on the flange part, leading to mechanical weakness and reliability issues in electronic devices.
Innovation Solution
A coil component design featuring a drum core with a winding shaft and flange parts, where lead parts are routed into a single or multiple groove parts on the flange's exterior face, dispersing impact forces and enhancing mechanical strength by reducing the thin region of the flange part, thus preventing damage and terminal separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead parts are connected to metal film on flange part exterior face by flattening or soldering, then terminal connection is achieved, but impact force concentrates on flange part causing damage and terminal separation
Solution Approach 1:
The flange part exterior face is segmented into multiple groove parts, distributing the lead part connections across different locations. This segmentation prevents concentration of impact forces at a single point, thereby maintaining terminal connection integrity while preserving flange part mechanical strength.
Solution Approach 2:
Groove parts are created with specific local structural characteristics (cut-out parts on side faces) to accommodate lead parts. These localized structural modifications provide dedicated connection zones that reduce stress concentration on the overall flange part, resolving the contradiction between reliable terminal connection and mechanical strength.
2Strength
If groove parts are provided on flange part exterior face, then impact forces are dispersed and mechanical strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
Groove parts are formed on the flange part exterior face during the drum core manufacturing process, before final assembly. This preliminary formation of grooves integrates the structural reinforcement feature into the base manufacturing flow, minimizing additional manufacturing complexity while achieving enhanced mechanical strength and impact force dispersion.
Data Source
AI summary
A coil component includes: a core part including: a winding shaft, and a flange part provided on an axial-direction end of the winding shaft, which has an exterior face on the opposite side of the winding shaft, first and second side faces, and first and second groove parts provided on the exterior face and having a cut-out part on each the first and second side faces; a coil part including: a winding part of a conductor wound around the winding shaft, and two lead parts of the conductor led out from the winding part; and two terminal parts formed on the exterior face of the flange part; wherein the two lead parts are led in from the cut-out parts on the first and second side faces and fitted inside the groove parts, respectively, on the exterior face, and included in the pair of terminal parts, respectively.