Surface-Mounted Inductor with Parallel Winding Axis
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Solution Overview
Problem
Past surface-mounted inductors face challenges in achieving low resistance and high insulation breakdown voltage due to excess resistance in the conduction path and difficult manufacturing processes, particularly when exposing the extended coil end portions on the mounting surface.
Innovation Solution
A surface-mounted inductor design where the coil's winding axis is parallel to the mounting surface, with extended parts exposed from the molded body's surface, and a lower magnetic powder density between the end portions on the mounting surface-side, allowing for shorter connections and improved insulation breakdown voltage, achieved through a specific manufacturing method using a composite material and reserve molded bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is disposed with the winding axis perpendicular to the mounting surface, then the manufacturing process is simplified, but the resistance increases due to the longer conduction path
Solution Approach 1:
The patent inverts the conventional coil orientation by disposing the winding axis parallel to the mounting surface instead of perpendicular. This inversion shortens the conduction path distance from the coil end portion to the mounting surface, thereby reducing resistance while maintaining manufacturing feasibility through the support pin structure
2Reliability
If the end portion of the extended part of the coil is exposed on the mounting surface, then the resistance is reduced, but the manufacturing quality deteriorates due to difficult processing
Solution Approach 1:
The patent applies preliminary action by providing a support pin that protrudes from the base part of the cavity before molding. This support pin pre-positions the coil with its end portion exposed on the mounting surface side, eliminating the need for difficult post-processing to expose the coil end and ensuring consistent positioning accuracy
3Ease of manufacture
If the density of magnetic powder is uniform throughout the molded body, then the manufacturing process is simplified, but the insulation breakdown voltage between outer terminals decreases
Solution Approach 1:
The patent applies local quality by creating a region with lower magnetic powder density between the end portions of the extended parts on the mounting surface side. This localized density reduction increases the insulation breakdown voltage between outer terminals, while the support pin ensures this density variation does not compromise the overall structural integrity or positioning precision
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 solution results in a surface-mounted inductor with reduced resistance and enhanced insulation breakdown voltage, improving manufacturing stability and electrical characteristics.
Implementation Method 1
a molded body, constituted by a composite material containing a magnetic powder, that contains the coil
Data Source
AI summary
A surface-mounted inductor including a coil having a wound part formed by winding a conductive wire and extended parts extended from an outer circumference of the wound part, a molded body containing the coil, constituted by a composite material containing a magnetic powder, and outer terminals connected to end portions of the extended parts disposed on a mounting surface. The wound part is contained within the molded body so that a winding axis is parallel to the mounting surface. The extended parts are extended toward the mounting surface side, each end portion of the extended parts are exposed from the surface thereof of the molded body. In the molded body, a density of a magnetic powder between the end portions of the extended parts on the mounting-side surface is lower than a density in the surface on the opposite side from the mounting surface.