T-Shaped Core Coil Device Recesses for Adhesion
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Solution Overview
Problem
Existing coil devices face challenges in achieving high magnetic properties and preventing air gaps and misalignment due to the difficulty in filling spaces between the coil and the columnar portion with exterior material during manufacturing, leading to reduced adhesion and yield.
Innovation Solution
A coil device design featuring a T-shaped core with recesses extending from the columnar portion to the flange, allowing the exterior material to flow into these spaces and fill gaps, thereby enhancing magnetic properties and adhesion between the coil and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional molding techniques are used to cover the coil with exterior material, then the coil device can be manufactured, but air gaps form between the coil and columnar portion leading to reduced magnetic properties and adhesion
Solution Approach 1:
The patent applies preliminary action by forming recesses in the columnar portion before coil winding, and filling these recesses with exterior material after coil assembly. This pre-prepared structure guides the exterior material into the spaces between the coil and columnar portion, ensuring complete filling and eliminating air gaps that would otherwise form during traditional molding.
Solution Approach 2:
The recesses act as intermediaries that facilitate the flow of exterior material into the difficult-to-reach spaces between the coil and columnar portion. By creating these intermediate channels, the patent enables the exterior material to reach and fill all gaps, improving both adhesion and magnetic properties without requiring complex molding techniques.
2Reliability
If exterior material is compressed to fill spaces between coil and core, then adhesion improves, but manufacturing complexity increases due to difficulty in material flow control
Solution Approach 1:
The recesses are pre-formed in the columnar portion before coil assembly, creating built-in channels that guide exterior material flow. This preliminary structuring simplifies the compression process by providing natural pathways for material distribution, eliminating the need for complex molding techniques while ensuring complete space filling and improved adhesion.
3Productivity
If the cavity is filled with exterior material to cover the coil, then the coil device is manufactured, but misalignment occurs between the coil and columnar portion reducing yield
Solution Approach 1:
The recesses are formed in the columnar portion before coil winding, and their positions and dimensions are precisely controlled during core manufacturing. This preliminary precision work ensures that when exterior material fills the recesses, it automatically aligns the coil with the columnar portion, reducing misalignment and improving manufacturing yield.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents air gaps and improves the magnetic properties and yield of the coil device by ensuring the exterior material fills the spaces between the coil and the core, enhancing adhesion and reducing misalignment.
Implementation Method 1
filling the cavity with an exterior material including magnetic particles and a resin so that part of the exterior material flows into the recess
Implementation Method 2
an exterior body covering the coil and the columnar portion and made of an exterior material including magnetic particles and a resin
Data Source
AI summary
A coil device 1 comprises a coil 10, a T-shaped core 20 including a columnar portion 21 around which the coil 10 is disposed and a flange 22 formed at a first end 21a of the columnar portion 21 in an axial direction thereof, and an exterior body 30 covering the coil 10 and the columnar portion 21 and made of an exterior material including magnetic particles and a resin. The core 20 is provided with a recess 40 including at least one of a first recess 41 or a second recess 42. The first recess 41 extends between the first end 21a and a second end 21b of the columnar portion 21 in the axial direction. The second recess 42 extends from an inner side towards an outer side of the flange 22.