Wire-Wound Core Flange Geometry for Single-Dip Terminal Electrodes
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Solution Overview
Problem
The existing manufacturing process for wire-wound coil components requires multiple dipping operations to form terminal electrodes with diagonally extending edges, leading to decreased productivity due to the complexity of forming conductive paste layers on flanges with such edges.
Innovation Solution
A wire-wound core design featuring inclined surfaces on the flanges allows for the formation of terminal electrodes with a single dipping operation, where the conductive paste layer extends further along the outer end surface than the inner end surface, enabling efficient wetting and formation of a raised portion on the inclined surface during dipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminal electrodes with diagonally extending edges are formed, then the plating area is increased and solder fillet formation is improved, but the number of dipping operations increases to multiple steps
Solution Approach 1:
The flange is pre-formed with an inclined surface at a predetermined angle (45-85 degrees) before the dipping process. This preliminary geometric preparation enables the conductive paste to automatically form the desired diagonal edge shape during a single dipping operation, eliminating the need for multiple dipping steps while achieving precise terminal electrode geometry.
2Area of stationary object
If terminal electrodes with diagonally extending edges are formed, then the plating area is increased, but the manufacturing process complexity increases
Solution Approach 1:
The inclined surface is applied locally to specific regions of the flange (outer end surface or side surfaces) rather than uniformly across the entire flange. This localized geometric modification targets only the areas that contribute to plating area enhancement, while keeping other flange regions simple for easy manufacturing. The conductive paste selectively accumulates on the inclined surface during dipping, creating the diagonal edge shape only where needed.
3Productivity
If a single dipping operation is used, then productivity is improved, but forming terminal electrodes with extended outer end surface coverage is difficult
Solution Approach 1:
The inclined surface angle is optimized within a specific range (45-85 degrees) to control the conductive paste accumulation behavior during dipping. By adjusting this geometric parameter, the paste naturally extends further along the outer end surface while maintaining sufficient distance from the wound core. This parameter optimization enables single-step formation of precisely controlled terminal electrode shapes with extended plating areas.
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
This design enhances productivity by allowing terminal electrodes to be formed in a single step while maintaining sufficient distance between the terminal electrode and the wound core, ensuring a longer plating area and improved stability during mounting.
Implementation Method 1
the conductive paste layer in which, when measured in a direction from the bottom surface toward the top surface, a dimension of a portion extending along the outer end surface is longer than a dimension of a portion extending along the inner end surface is formed by pushing the first flange and the second flange simultaneously toward the conductive paste during the dipping
Data Source
AI summary
A wire-wound core includes a wound core portion and a first flange and a second flange provided on a first end portion and a second end portion, respectively. The first flange has a bottom surface facing a mounting substrate during mounting, a top surface facing away from the bottom surface, an inner end surface coupling the bottom surface with the top surface and facing the wound core portion, an outer end surface facing away from the inner end surface, and a first side surface and a second side surface that face away from each other and each couple the bottom surface with the top surface and the inner end surface with the outer end surface. In a region of the outer end surface close to the bottom surface, a first inclined surface inclined toward the inner end surface as the first inclined surface approaches the bottom surface is provided.