Octagonal Flange Coil Component for High-Density Mounting
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Solution Overview
Problem
Existing coil components face challenges in achieving high-density mounting due to increased height and potential for short-circuiting, along with issues in resin overflow and air bubble trapping during manufacturing, which affect electrical connection integrity and core strength.
Innovation Solution
A coil component design with an octagonal flange and terminal electrodes positioned on the peripheral surfaces, allowing for reduced height and increased surface area for bonding, combined with a manufacturing method using a die with a resin supplying cell and communicating part to control resin flow and prevent overflow, ensuring accurate resin distribution and minimizing air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal electrodes are provided on the mounting surface to enable electrical connection, then electrical connection is achieved, but the height of the coil component increases
Solution Approach 1:
The terminal electrodes are relocated from the mounting surface (bottom face) to the peripheral surfaces of the flanges, changing the spatial dimension of electrode placement. This allows electrical connections to be made from the side rather than from below, reducing the height requirement while maintaining connection functionality
Solution Approach 2:
Instead of providing electrodes on the bottom mounting surface as in conventional designs, the invention inverts the approach by placing electrodes on the peripheral surfaces of the flanges, fundamentally changing the connection interface orientation
2Difficulty of detecting and measuring
If terminal electrodes are provided on the peripheral surface of the flange to make connections visible, then electrical connection visibility is improved, but short-circuiting occurs between adjacent coil components
Solution Approach 1:
The flange is designed with an octagonal cross-section featuring asymmetric electrode placement. Terminal electrodes are positioned on alternate peripheral surfaces (first and third for one electrode, second and fourth for another), creating an asymmetric pattern that provides visibility while maintaining spacing to prevent short-circuiting between adjacent components
Solution Approach 2:
The peripheral surface of the flange is segmented into multiple distinct surfaces, with terminal electrodes placed on specific alternating surfaces rather than continuously around the periphery. This segmentation isolates the electrodes and prevents electrical interference between adjacent coil components
3Productivity
If resin is quickly flowed into the recess to fill the gap between flanges, then manufacturing speed is improved, but air bubbles are trapped in the resin
Solution Approach 1:
The drum core with winding is pre-positioned in the recess before resin injection, and the resin is supplied from the bottom upward. This preliminary arrangement ensures that air bubbles can escape upward through the winding as resin fills the space, preventing bubble entrapment even during rapid filling
Solution Approach 2:
The winding itself acts as an intermediary structure that facilitates air bubble escape. As resin flows upward through and around the winding, air bubbles are carried upward along with the resin flow and can escape through the top, preventing bubble entrapment in the final cured resin
4Strength
If resin is firmly fixed about the winding to fill the gap between flanges, then core strength is improved, but resin overflows from the recess onto terminal electrodes
Solution Approach 1:
The octagonal flange design with chamfered corners creates localized geometric features that control resin flow. The specific angles and surfaces of the octagonal cross-section guide resin to fill the gap between flanges uniformly without overflowing onto the terminal electrodes positioned on alternate peripheral surfaces
Data Source
AI summary
A coil component having a core including a winding portion, and first and second flanges disposed one on either end of the winding portion, A winding is wound about the winding portion, and first and second terminal electrodes are disposed on the first flange. The first flange has an octagonal shape including a bottom surface, a first peripheral surface, first and third omitted peripheral surfaces disposed one on either side of the first peripheral surface, a second peripheral surface opposing the first peripheral surface, and second and fourth omitted peripheral surfaces disposed one on either side of the second peripheral surface. The first terminal electrode is disposed across the first omitted peripheral surface, a part of the bottom surface in a region connecting the entire first omitted side to the entire third omitted side, and the third omitted peripheral surface. The second terminal electrode is disposed across the second omitted peripheral surface, a part of the bottom surface in a region connecting the entire second omitted side to the entire fourth omitted side, and the fourth omitted peripheral surface. The winding has a first end electrically connected to the first terminal electrode on the first omitted peripheral surface and a second end electrically connected to the second terminal electrode on the second omitted peripheral surface.