Loop Type Coil Low Back Design for Solder Fillet Inspection
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Solution Overview
Problem
Existing loop type coil parts face challenges in achieving a low back type design while ensuring sufficient fillet formation for solder quality confirmation, as thick flanges are required for large fillets, increasing height, and thin flanges lack sufficient electrode area for inspection.
Innovation Solution
A loop type coil part design featuring a protruding part on the side surface of the flange with a recess on the bottom surface, allowing terminal electrodes to be continuous across both surfaces, forming a fillet with an oblique surface for visual inspection without increasing flange thickness or height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thickness of the flange is increased to form a large fillet for solder quality confirmation, then the fillet size is improved, but the height size of the coil part becomes high
Solution Approach 1:
The invention transitions the fillet formation from a two-dimensional bottom surface groove to a three-dimensional structure involving the side surface. By providing a protruding part on the side surface and forming a fillet that connects to it, the inspection area is extended into the vertical dimension without increasing the overall height of the coil part.
Solution Approach 2:
The flange structure is segmented into a protruding part and a non-protruding part, with the terminal electrode continuously provided across both. This segmentation allows the fillet to be formed in multiple locations (bottom surface and side surface), distributing the inspection area across different surfaces rather than concentrating it in one large groove.
2Length of stationary object
If the thickness of the flange is decreased to obtain a low back type coil part, then the height size is reduced, but the electrode area for fillet confirmation becomes insufficient
Solution Approach 1:
By utilizing the side surface of the flange through the protruding part, the invention creates additional electrode area in the vertical dimension. This allows sufficient fillet confirmation area to be achieved without increasing the horizontal dimensions or overall height of the coil part.
Solution Approach 2:
The terminal electrode serves multiple functions: it provides electrical connection on the bottom surface, extends to the side surface through the protruding part, and creates multiple surfaces for fillet formation. This multi-functionality maximizes the utility of the electrode structure within the constrained height.
3Manufacturing precision
If a deep and large groove is provided in the bottom surface to obtain a large fillet, then the fillet size is improved, but the manufacturing complexity and height increase
Solution Approach 1:
Instead of one large deep groove, the structure is segmented into a shallower groove in the bottom surface and a protruding part on the side surface. The terminal electrode continuously connects both regions, distributing the fillet formation across multiple smaller surfaces rather than requiring one large complex groove.
Solution Approach 2:
The groove in the bottom surface can be shallower than traditionally required, as the protruding part on the side surface provides additional area for fillet formation. This partial action approach allows the groove to be less deep while still achieving sufficient total fillet area through the combination of bottom surface and side surface.
Data Source
AI summary
One inventive aspect relates to a low back type loop type coil part which may facilitate confirmation of quality of soldering. The loop type coil part comprises a core including a spool arranged vertically to a mounting side and a plate-like flange provided at an end of the spool to come in contact with the mounting side. A coil lead is wound around the spool, and an end of the coil lead is soldered and fixed to a terminal electrode of a bottom surface of the flange. A protruding part is provided at a part of a side surface of the flange in a length direction. A recess is formed in the bottom surface of the flange so as to be in contact with the protruding part of the side surface and a non-protruding part adjacent to the protruding part. The terminal electrode is provided to be continuous across an inner wall surface of the recess, a bottom surface of the protruding part, and a bottom surface of the non-protruding part. Accordingly, by using the protruding size of the flange, the fillet to facilitate confirmation of quality of soldering can be formed without increasing the thickness size of the flange of the core and the height size of the core.