Jagged-Edge Coil Component for Oxidation-Resistant Inductance
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Solution Overview
Problem
Conventional coil components face challenges in maintaining effective magnetic flux and inductance characteristics due to issues with magnetic particle exposure and oxidation, leading to potential rust and deformation, which can degrade their soft magnetic properties.
Innovation Solution
A coil component design featuring an exterior body with a jagged edge and a polyhedral or columnar shape, made from a magnetic material and resin, where the exterior body is formed with a jagged edge to prevent exposure and oxidation, and a method of producing the component by filling a mold with magnetic particles and resin, allowing the exterior body to be easily disconnected without cutting, thus avoiding surface exposure and maintaining magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the exterior body is made with smooth edges from magnetic particles and resin, then the manufacturing process is simple, but the magnetic particles are exposed and oxidized leading to rust and deformation
Solution Approach 1:
The exterior body is designed with jagged edges instead of smooth edges, creating an asymmetric surface morphology that prevents magnetic particle exposure and oxidation while maintaining manufacturing simplicity through the molding process
Solution Approach 2:
The jagged edge structure is formed during the molding process itself, performing the protective function in advance before oxidation can occur, eliminating the need for post-manufacturing protective treatments
2Productivity
If the exterior body is cut to separate components, then the production efficiency is improved, but the cutting process exposes magnetic particles to oxidation and deformation
Solution Approach 1:
The mold is divided into multiple detachable sections that can be separated without cutting the exterior body, allowing efficient component removal while preserving the integrity and protective jagged edge structure
Solution Approach 2:
The mechanical cutting process is replaced with a mold detachment mechanism, substituting a harmful mechanical cutting action with a non-contact or minimal-contact separation method that avoids exposing magnetic particles to oxidation
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 the inductance characteristics and reliability of the coil component by preventing oxidation and deformation, while simplifying the production process and reducing material costs.
Implementation Method 1
filling the partitioned areas with an exterior material including magnetic particles and a resin and also filling at least part of connection areas connecting the partitioned areas next to each other with the exterior material; forming a molded article comprising exterior bodies made from the exterior material filled in partitioned areas and joining parts made from the exterior material filled in the connection areas to join the exterior bodies via the joining parts
Implementation Method 2
the exterior body has a jagged edge on at least part of an edge positioned between the second plane and the one or more connecting planes... to prevent exposure and oxidation
Data Source
AI summary
A coil component includes an exterior body, a coil positioned inside the exterior body, and terminal electrodes arranged on a surface of the exterior body and connected to lead parts of the coil. The exterior body is a columnar shape or a polyhedron shape, and includes a first plane for arranging the terminal electrodes, a second plane opposing the first plane, and one or more connecting planes connecting the first plane and the second plane; and the exterior body has a jagged edge on at least part of an edge positioned between the second plane and the one or more connecting planes.