Inductor Top Plate Projection Geometry for Miniaturization
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Solution Overview
Problem
The existing inductor components with taper-shaped projections face challenges in miniaturization due to the need for a larger space on the top plate for projection arrangement, which restricts the miniaturization of both the top plate and the inductor component.
Innovation Solution
The inductor component design incorporates a top plate with projections that have a distal end face parallel to the principal surface and side surfaces with inclined and vertical components, reducing the projection arrangement space by eliminating the need for a shape that spreads towards the principal surface, allowing for a more compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projections have a taper shape with an inclined side surface, then contact area with flange portion is increased, but projection arrangement space on the top plate increases
Solution Approach 1:
The side surface of the projection is segmented into two distinct parts: an inclined surface and a vertical surface. This segmentation allows the projection to have both a larger contact area (achieved through the inclined surface) and a smaller arrangement space (achieved through the vertical surface that does not spread toward the principal surface).
Solution Approach 2:
Different portions of the projection's side surface are given different geometric properties. The inclined surface provides enhanced contact area where needed, while the vertical surface minimizes space occupation. This local differentiation of geometric quality resolves the contradiction between contact area and arrangement space.
2Volume of moving object
If the top plate is miniaturized, then the inductor component size is reduced, but the projection arrangement space becomes insufficient
Solution Approach 1:
By segmenting the side surface into inclined and vertical portions, the projection achieves efficient space utilization. The vertical surface portion minimizes the horizontal footprint, enabling compact top plate design while the inclined surface maintains adequate contact area for mechanical strength.
Solution Approach 2:
The projection design transitions from a purely two-dimensional taper shape to a three-dimensional form with both inclined and vertical surfaces. This dimensional complexity allows the projection to optimize both contact area and arrangement space simultaneously, enabling miniaturization of the overall component.
Data Source
AI summary
An inductor component includes a drum-shaped core, a wire, and a top plate. The drum-shaped core includes a winding core portion, a first flange portion, and a second flange portion. The winding core portion has a columnar shape extending along a central axis as a center. The first flange portion is connected to a first end of the winding core portion. The wire is wound around the winding core portion. The top plate is connected to the first flange portion. The top plate includes a first projection that protrudes toward the first flange portion. The first projection includes a distal end face that is parallel to a principal surface and a side surface that extends from the distal end face toward the principal surface. The side surface includes a vertical surface that is linked to a first end face and is flush with the first end face.