Surface-Mount Inductor Ridge Stabilization
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Solution Overview
Problem
Existing surface-mount inductors face issues with stability during production due to excessive stress applied during processing, leading to decreased quality and increased component count from bent terminal electrodes.
Innovation Solution
A surface-mount inductor design featuring a core with a base portion and columnar portion containing magnetic powder, a coil with wound conductive wire and extended portions, and external terminals, where the extended portions are disposed close to ridge portions on the base to stabilize contact positions and reduce stress, allowing for adjustable inductance and improved magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminal electrodes are extended from the element assembly and bent to form external terminals, then external terminals are formed, but the number of components increases and excessive stress is applied to the element assembly during processing
Solution Approach 1:
The patent integrates the external terminal function directly into the coil structure by extending the conductive wire itself to form external terminals, merging the coil and terminal electrode functions into a single component. This eliminates separate terminal electrode components and reduces overall device complexity while maintaining the ability to form external terminals.
Solution Approach 2:
The conductive wire serves multiple functions: it forms the coil winding for inductance, provides the extended portions for external connections, and acts as the terminal electrode. This multi-functionality reduces the number of separate components needed while maintaining ease of operation for terminal formation.
2Ease of operation
If terminal electrodes are extended and bent during processing, then external terminals are formed, but excessive stress is applied to the element assembly causing decreased quality stability
Solution Approach 1:
By merging the terminal electrode function into the coil's conductive wire, the patent eliminates separate bending operations on terminal electrodes. The extended portions of the conductive wire are directly formed as external terminals during coil winding, avoiding additional stress-inducing processing steps on the element assembly.
Solution Approach 2:
The external terminal portions are formed during the initial coil winding process rather than as a separate subsequent step. This preliminary formation of external terminals avoids later processing that would apply excessive stress to the element assembly, thereby maintaining quality stability during production.
3Adaptability or versatility
If the coil is wound on the columnar portion, then inductance can be adjusted, but the extended portions may be exposed and magnetic characteristics may deteriorate
Solution Approach 1:
The patent applies magnetic material selectively to cover only the columnar portion where the coil is wound, while leaving the base portion exposed. This local application of magnetic material provides the necessary magnetic characteristics and protects the coil winding, while the extended portions of the conductive wire are positioned to avoid exposure issues.
Solution Approach 2:
The patent positions the extended portions of the conductive wire in a specific spatial arrangement where they extend from the wound portion toward the side surface but are covered by the magnetic material. This three-dimensional positioning prevents exposure of the extended portions while maintaining inductance adjustability through coil winding variations.
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 design enhances production stability, allows for precise adjustment of inductance, and improves magnetic flux balance and direct current superposition characteristics, while reducing the risk of coil exposure and enhancing dielectric breakdown voltage.
Implementation Method 1
a core (30) including a base portion (34) having a lower surface at a mounting surface side, an upper surface at a side opposite to the mounting surface, side surfaces (34A) adjacent to the upper surface and the lower surface, and a columnar portion (32) disposed on the upper surface of the base portion, and containing magnetic powder in at least a partial region
Implementation Method 2
The core contains magnetic powder in at least a partial region. The magnetic material is formed to include the coil, cover at least a part of the core, and contain magnetic powder
Implementation Method 3
a coil (20) disposed on the base portion. The coil has a wound portion (22) formed by winding a conductive wire, having an insulating coating and having a pair of flat surface portions opposing each other, on the columnar portion
Data Source
AI summary
A surface-mount inductor includes an element assembly having a core, a coil, and a magnetic material; and a pair of external terminals on a mounting surface of the element assembly. The core has a base portion and a columnar portion on an upper surface of the base portion. The coil is disposed on the base portion, and has a wound portion on the columnar portion, and a pair of extended portions extended from the wound portion. The base portion has at least one ridge portion at which the upper surface and a side surface are in linear contact with each other. The pair of extended portions are each disposed such that a flat surface portion connected to a flat surface portion disposed at an inner side portion of a conductive wire located at an outer peripheral portion of the wound portion is close to the ridge portion.