Inductor Component Segmented Bonding for Miniaturization
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Solution Overview
Problem
Miniaturization of inductor components leads to unstable connecting strength between lead wires and metal terminals, and thermal deterioration of insulating films due to heat transfer during welding, resulting in decreased reliability.
Innovation Solution
The inductor component design includes a coil portion, lead-out portion, connection line portion, and terminal electrode, with a pair of first bonding pieces that elongate from the connection line portion to secure the lead-out portion, and laser welding is used to connect these parts, reducing heat exposure and enhancing bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a thin lead wire is used to form a small coil for miniaturization, then the inductor component size is reduced, but the connecting strength between the lead wire and metal terminal becomes unstable
Solution Approach 1:
The connection structure is segmented into multiple bonding pieces (first bonding pieces and second bonding pieces) that connect the lead wire to the terminal at multiple separate locations. This segmentation distributes the mechanical stress and strengthens the overall connection, preventing the lead wire from coming off despite the reduced size and thin gauge of the wire.
Solution Approach 2:
The bonding pieces extend in multiple directions (first bonding pieces in a first direction, second bonding pieces in a second direction) to create a multi-dimensional connection structure. This dimensional approach increases the connection area and provides redundant bonding paths, enhancing connecting strength while maintaining compact dimensions.
2Strength
If arc welding is used to connect the lead wire to the metal terminal, then the connection is achieved, but heat during fusion is transferred to the coil causing thermal deterioration of the insulating film
Solution Approach 1:
The patent replaces the thermal arc welding process with a mechanical bonding system using multiple bonding pieces that physically secure the lead wire to the terminal. This substitution eliminates the high-temperature heat source that would otherwise transfer to the coil and deteriorate the insulating film, while still achieving strong mechanical connection.
Solution Approach 2:
The bonding pieces act as intermediary elements between the lead wire and the terminal, providing a mechanical connection interface that does not require direct thermal contact. This intermediary structure allows force transmission without heat transfer, protecting the insulating film from thermal damage.
3Volume of moving object
If the coil is made smaller using a thin lead wire, then the inductor component is miniaturized, but the area of the connecting part between the lead wire and metal terminal becomes smaller reducing connecting reliability
Solution Approach 1:
The connection interface is segmented into multiple discrete bonding pieces distributed across the terminal surface. This segmentation increases the total bonding area and creates multiple independent connection points, thereby enhancing connecting reliability even when the overall component size and lead wire area are reduced.
Solution Approach 2:
The bonding pieces are arranged in multiple directions and dimensions on the terminal surface, maximizing the use of available area. This multi-dimensional arrangement increases the effective connecting area beyond what a single-plane connection would provide, improving reliability in the miniaturized structure.
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
This configuration improves connecting reliability and prevents thermal deterioration of the insulating film, ensuring the stability of miniaturized inductor components by providing dual bonding points and controlled heat distribution during welding.
Implementation Method 1
The lead-out portion and the connection line portion are connected by means of fusion bonding between the part of the lead-out portion on the opposite side from the connection line portion and distal end parts of the first bonding pieces
Implementation Method 2
laser welding is used to connect these parts, reducing heat exposure and enhancing bonding strength
Data Source
AI summary
The inductor component includes: coil portion around which lead wire is wound; lead-out portion at which an end portion of the lead wire is led out; connection line portion to which the lead-out portion is connected; outer terminal portion integrally formed with the connection line portion; and mold body which contains a magnetic material and in which the coil portion and the connection line portion are embedded. The connection line portion has a shape elongating along the lead-out portion, and includes a pair of first bonding pieces between the coil portion and terminal of the lead-out portion, the pair of first bonding pieces elongating from both sides of the connection line portion in mutually opposite directions. The pair of first bonding pieces has distal end sides each folded toward a part of the lead-out portion on the opposite side from the connection line portion.