Electronic Component Oblique Wire Cut for Low DC Resistance
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Solution Overview
Problem
Conventional electronic components with coils buried in composite magnetic materials face increased DC resistance due to limited contact area between led-out ends and external terminal electrodes, making them larger in size to achieve sufficient inductance, which is undesirable for compact and high-performance devices.
Innovation Solution
The electronic component features led-out ends of the coil with cut surfaces obliquely cut relative to the coil surface, exposed on the molded body surface, allowing a greater led-out angle greater than 90 degrees, thereby increasing the contact area with external terminal electrodes without enlarging the component size or requiring special processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of electrically-conductive wire is increased to increase contact area, then DC resistance decreases, but component size increases
Solution Approach 1:
The invention changes the contact geometry from a point contact (wire end on flat surface) to a line contact by obliquely cutting the wire. This dimensional change from 0D point to 1D line contact increases the contact area without requiring thicker wire, thus reducing DC resistance while maintaining compact size.
Solution Approach 2:
The invention changes the geometric parameter of the wire end from a flat perpendicular cut to an oblique cut at a specific angle. This parameter change transforms the contact surface from a small circular area to a larger elliptical area, improving electrical contact without increasing wire thickness or component size.
2Ease of manufacture
If led-out ends are cut perpendicular to surface, then manufacturing is simple, but contact area with terminal electrode is insufficient
Solution Approach 1:
The invention modifies the cutting angle parameter from 90 degrees (perpendicular) to an oblique angle between 45-60 degrees. This parameter change increases the contact area of the wire end with the terminal electrode while remaining compatible with standard cutting processes, thus balancing manufacturing ease with improved electrical contact.
Data Source
AI summary
A coil is formed by winding an electrically-conductive wire, and is buried in a molded body formed from a composite magnetic material containing a magnetic powder and a resin. Each of led-out ends of the coil has a cut surface formed by obliquely cutting an electrically-conductive wire with respect to a surface thereof. The cut surface of each led-out end of the coil is exposed on a surface of the molded body, and each led-out end is connected to an external terminal electrode formed in the surface of the molded body at the cut surface.