Substrate-Mounting Inductor with Recessed Terminal
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Solution Overview
Problem
Conventional inductors using Mn—Zn-based ferrite as a core material face insulation failures between the winding and core, leading to increased height due to the need for resin molding bodies for electrical insulation, which complicates the design and increases the device's profile.
Innovation Solution
A substrate-mounting type inductor design featuring a recessed portion on the core's substrate mounting surface to house the terminal portion through an insulating member, allowing the terminal to be integrated within the core's height and eliminating the need for external terminals, thereby reducing the device's height and maintaining electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin molding body is arranged below the core to electrically insulate the mounting substrate from the core, then electrical insulation is secured, but the height dimension of the inductor increases by the thickness of the resin molding body
Solution Approach 1:
The terminal portion is nested within a recessed portion formed on the core itself, eliminating the need for an external resin molding body. The insulating member is housed within the recessed portion, integrating the insulation function into the core structure rather than adding external components, thereby reducing the overall height dimension while maintaining electrical insulation.
Solution Approach 2:
Instead of arranging the insulating member in a direction perpendicular to the core (below the core), the invention utilizes the height dimension of the core by forming a recessed portion on the core surface. This repositions the insulating member within the core's vertical space, effectively using the core's height to accommodate insulation without increasing the overall inductor height.
2Reliability
If an insulating member is interposed between the core and mounting substrate, then electrical insulation is achieved, but the inductor size increases in horizontal direction
Solution Approach 1:
The insulating member is nested within the recessed portion of the core, completely integrating it into the core structure. This prevents the insulating member from projecting outside the inductor's horizontal boundaries, thereby maintaining a compact footprint while providing necessary electrical insulation.
Data Source
AI summary
In substrate-mounting type inductor having a winding having conductivity, a core on which the winding is winded, and a terminal portion arranged at an end of the winding, a recessed portion which is recessed in a direction of height of the core is formed on a substrate mounting surface of the core, and the terminal portion is arranged to be housed in the recessed portion through an insulating member.