Magnetic Plate Structure for Crack-Resistant Coil Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The quality of existing coil components degrades due to cracks and chips in the magnetic plate's concave storage portion, leading to defects during manufacturing and usage.
Innovation Solution
A coil component design featuring a magnetic plate with an annular first planar portion, a second planar portion inside the first, and a connection surface with inclined slopes and chamfered portions to prevent cracks and chips, ensuring easy molding and attachment, and controlling magnetic efficiency and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a magnetic plate with a concave storage portion is manufactured, then adhesive can be stored for bonding, but cracks and chips are likely to be generated in the storage portion
Solution Approach 1:
The connection surface portion is formed with multiple inclined slopes (first slope, second slope, third slope) instead of a single concave portion. This curved/angled surface structure eliminates stress concentration points while providing adequate space for adhesive storage and bonding, thereby preventing cracks and chips.
Solution Approach 2:
The invention changes the geometric parameters of the connection surface from a deep concave shape to a series of inclined planes with specific angle ranges (30-60 degrees for the second slope). This parameter optimization maintains adhesive storage capability while reducing stress concentration that leads to defects.
2Device complexity
If a magnetic plate with a simple flat structure is used, then manufacturing is simpler, but molding difficulty increases and defects occur
Solution Approach 1:
The connection surface portion incorporates inclined slopes with optimized angle ranges (30-60 degrees for the second slope), which facilitates mold filling during injection molding and enables easy removal of the magnetic plate from the mold after curing, significantly improving manufacturability.
Solution Approach 2:
The connection surface is divided into multiple segmented slopes (first, second, third slopes) with different inclination angles. This segmentation optimizes both mold filling behavior and demolding ease while maintaining structural integrity, resolving the contradiction between complexity and ease of manufacture.
Data Source
AI summary
A coil component includes a core including a winding core portion and a pair of flange portions provided at both ends of the winding core portion, electrode portions provided in the flange portions, a wire wound around the winding core portion, and a magnetic plate fixed to the flange portions. The magnetic plate includes an annular first planar portion, a second planar portion that is located inside the inner circumference of the first planar portion and has a step between the first and the second planar portions, and a connection surface portion connecting the inner circumference of the first planar portion to the outer circumference of the second planar portion. The connection surface portion is configured by annularly disposing at least three slopes inclined with respect to the direction orthogonal to the first planar portion and has chamfered portions each being disposed between adjacent slopes.