Wire-Wound Coil Layout for Thin, Breakage-Resistant Mounting
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Solution Overview
Problem
Conventional wire-wound coil elements, especially those mounted horizontally, face challenges in reducing thickness without compromising structural integrity, as thinner flanges and winding cores are prone to breakage under mounting stress.
Innovation Solution
A wire-wound coil element with a rectangular parallelepiped shape where the winding core extends along the short sides of the principal surface, featuring flanges with larger thickness perpendicular to the mounting surface, and a resin layer to reinforce the structure, allowing for efficient arrangement of windings between flanges and reducing the risk of breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of flanges is reduced to achieve reduced coil element thickness, then the thickness parameter is improved, but the flanges become prone to breakage under mounting stress
Solution Approach 1:
The patent changes the orientation of the winding core from extending along the long sides to extending along the short sides of the coil element. This dimensional reconfiguration allows the flanges to be positioned at the ends of the winding core along the short sides, enabling reduced thickness in the long side direction while maintaining adequate flange thickness perpendicular to the mounting surface for strength.
Solution Approach 2:
The patent applies different thickness characteristics to different parts of the structure. The flanges have larger thickness perpendicular to the mounting surface to ensure breakage resistance, while the overall coil element achieves reduced thickness through the reconfigured winding core orientation, creating a local optimization of thickness distribution.
2Length of moving object
If the diameter of winding core is reduced to achieve reduced thickness of horizontally mounted coil element, then the thickness parameter is improved, but the winding core becomes prone to breakage by stress
Solution Approach 1:
The patent reconfigures the winding core to extend along the short sides instead of the long sides of the coil element. This dimensional change allows the winding core to maintain sufficient diameter for strength while achieving reduced overall thickness through the optimized arrangement along the shorter dimension.
3Quantity of substance
If conventional horizontally mounted coil elements are arranged with winding core extending along long sides to maximize turns, then the inductance is improved, but the thickness increases and breakage risk increases
Solution Approach 1:
The patent rotates the winding core orientation from along the long sides to along the short sides of the coil element. This reconfiguration allows the windings to be arranged efficiently in the available space between flanges along the short side direction, achieving adequate number of turns while reducing the thickness dimension.
Data Source
AI summary
A coil element according to one embodiment of the present invention has a rectangular parallelepiped shape and has a principal surface including long sides and short sides. The coil element includes a drum core, a winding wound around the drum core, a first external electrode, a second external, and a covering portion covering at least a part of the winding core. The drum core in the embodiment includes a first flange, a second flange, and a winding core connecting between the first flange and the second flange. The winding core extends along the short sides of the principal surface. In one embodiment, the coil element has a height less than 0.85 mm.