3D Printed Integrated Coil Component Eliminating Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing toroidal coils are labor-intensive and prone to reliability issues due to bonding steps, and miniaturization is limited by the insufficient strength of conductive wires, making it difficult to produce small-sized coils with high inductance values.
Innovation Solution
A wire wound-type coil component with an integrated structure featuring a non-conductive annular core, spiral conductive wire, and terminal electrodes, where the core and coil conductor form a closed magnetic path, and a shape holding member made of insulating material is used to enhance strength and reliability, manufactured using a 3D printer to eliminate bonding portions and achieve miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operations are used to pass conductive wire through core through-holes, then coil component reliability is maintained, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The core and coil conductor are merged into a single integrated component manufactured by 3D printing, eliminating the need for separate assembly steps where conductive wire is passed through core through-holes. This integration maintains reliability by removing bonding interfaces while simplifying the manufacturing process to a single additive manufacturing operation.
Solution Approach 2:
The manual mechanical operation of passing wire through holes and bonding it is replaced by an automated 3D printing process that directly deposits conductive material to form the coil conductor integrated with the core. This substitution eliminates labor-intensive steps while maintaining the mechanical integrity of the connection.
2Extent of automation
If bonding steps are added to manufacture toroidal coils, then manufacturing automation is improved, but reliability decreases due to bonding portion weaknesses
Solution Approach 1:
The core and coil conductor are combined into a single monolithic structure manufactured by 3D printing, eliminating all bonding interfaces. This integration removes the reliability weaknesses associated with bonding portions while the entire manufacturing process is automated through additive manufacturing technology.
3Strength
If conductive wire strength is insufficient, then miniaturization is limited, but larger coil components are required for high inductance values
Solution Approach 1:
The 3D printing process creates a composite structure where the core and coil conductor are formed from different materials with optimized properties. The conductive material is deposited with sufficient strength to support miniaturization, while the magnetic core material provides the necessary inductance properties in a compact form factor.
Solution Approach 2:
The 3D printing process enables precise control of material deposition parameters, allowing the conductive material to be printed with optimized geometric parameters and material properties that provide sufficient strength for miniaturized applications while maintaining the required inductance values.
4Ease of manufacture
If 3D printing is used to manufacture integrated coil components, then manufacturing steps are reduced, but new manufacturing technology requirements arise
Solution Approach 1:
Traditional mechanical manufacturing and assembly processes are replaced by 3D printing technology, which consolidates multiple manufacturing steps into a single additive manufacturing operation. This substitution reduces the number of manufacturing steps while requiring adaptation to additive manufacturing capabilities and material systems.
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 provides a high-reliability, miniaturized coil component with improved mechanical strength and reduced stray capacitance, enabling efficient surface mounting and enhanced environmental resistance, while maintaining high inductance values.
Implementation Method 1
a step of three-dimensionally shaping the core, the coil conductor, and a shape holding member for holding a shape of a wall surface of the core defining the through-hole, by using a 3D printer
Implementation Method 2
a magnetic flux passes through the core while being confined in the annular core, whereby a closed magnetic path is formed. Therefore, the magnetic flux in the core is not affected by change in the state outside the core
Data Source
AI summary
A wire wound-type coil component with an integrated structure does not have a bonding portion where there is concern about reliability with respect to a spiral conductive wire, a terminal electrode, and an annular core. A coil component includes a core with an integrated structure, at least part of which is a winding core portion, which has an annular shape having a through-hole, and which is made of a non-conductive material; and a coil conductor with an integrated structure, which has a spiral conductive wire arranged to spirally extend around the winding core portion and first and second terminal electrodes formed at both end portions of the spiral conductive wire, respectively. The coil component is manufactured through three-dimensionally shaping the core, the coil conductor, and a shape holding member for holding a shape of a wall surface of the core defining the through-hole, by using a 3D printer.