PCB Coil Layout With Raised Terminals for Higher Thrust
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Solution Overview
Problem
In conventional printed wiring boards, the placement of external connection terminals on either the first or second main surface reduces the available area for the coil wires, thereby decreasing the thrust of the coil.
Innovation Solution
The coil device incorporates at least one printed wiring board with a first and second coil wire spirally formed on each main surface, a protective layer covering one main surface, and an external connection terminal formed on the protective layer, allowing for improved coil wire area utilization and thrust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the external connection terminal is disposed on the first main surface or second main surface, then the electrical connection is achieved, but the area available for coil wire placement is reduced and coil thrust decreases
Solution Approach 1:
The patent moves the external connection terminal from the two-dimensional plane of the main surface to the third dimension by forming it on the protective layer that covers the main surface. This dimensional transition allows the terminal to occupy space above the coil wire area rather than competing for the same planar space, thereby maintaining full coil wire placement area while achieving electrical connection.
Solution Approach 2:
The protective layer serves as an intermediary substrate that carries the external connection terminal. Instead of placing the terminal directly on the main surface where it would block coil wire placement, the protective layer acts as a mediator that provides a platform for the terminal while allowing the coil wires to be formed underneath it on the main surface.
2Force
If the coil wire area is increased to improve thrust, then the coil performance is enhanced, but the space for external connection terminal placement is reduced
Solution Approach 1:
By forming the external connection terminal on the protective layer that overlays the main surface, the patent utilizes the vertical dimension to separate the terminal from the coil wire plane. This allows maximum expansion of coil wire area on the main surface for enhanced thrust while the terminal is accommodated on the protective layer above, eliminating the trade-off between thrust and terminal placement area.
Data Source
AI summary
A coil device has a first surface and a second surface as end surfaces of the coil device in a thickness direction. The coil device includes at least one printed wiring board, a first protective layer, and an external connection terminal. Each of the at least one printed wiring board has a first base film including a first main surface and a second main surface as a surface opposite to the first main surface, a first coil wire spirally formed on the first main surface, and a second coil wire spirally formed on the second main surface. The first protective layer covers the first main surface of one of the at least one printed wiring board disposed closest to the first surface. The external connection terminal is formed on the first protective layer, and is electrically connected to the first coil wire.