Wire-Wound Component Core with Tapered Flange Corners
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Solution Overview
Problem
Conventional wire-wound electronic components experience chips or cracks during the molding process due to friction between the magnetic core's flanges and molding dies, which reduces the winding area and limits the number of turns or diameter of the winding wire, thereby restricting inductance improvement.
Innovation Solution
The design incorporates flanges with concaves at their corners, where the connecting surfaces between the flanges and the winding core portion have normal vectors aligned with the molding-die pull-away direction, reducing friction and preventing chips or cracks, and allowing the winding core portion to have an extended winding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flanges are provided with side surfaces parallel to the pull-away direction, then the flanges can protect the winding portion from heat, but friction occurs during pull-away causing chips or cracks
Solution Approach 1:
The patent applies curvature by replacing flat side surfaces with tapered surfaces that have a specific angle (α) relative to the pull-away direction. This curved/tapered geometry allows the molding die to separate smoothly from the flange during pull-away, eliminating friction and preventing chips or cracks while maintaining the protective function of the flanges
2Object-affected harmful factors
If taper surfaces are provided at both ends of the winding core portion, then friction during pull-away is suppressed, but the winding area is reduced
Solution Approach 1:
The patent applies local quality by providing tapered surfaces only at specific locations (corners) of the flanges rather than across the entire winding core portion. The tapered surfaces are localized to the regions where friction occurs during pull-away, while the central winding area remains flat and maximized for optimal winding capacity
3Device complexity
If flanges are made with parallel side surfaces, then the structure is simple, but chips or cracks occur during the molding process
Solution Approach 1:
The patent introduces tapered surfaces with a specific angle (α) at the flange corners, replacing purely parallel side surfaces. This moderate geometric modification is simple to implement in molding while effectively preventing chips and cracks by eliminating friction during the pull-away process
Data Source
AI summary
A wire-wound electronic component, a core for a wire-wound electronic component and a method for manufacturing a core for a wire-wound electronic component are provided. A winding core portion of a core of a wire-wound electronic component includes flanges at respective ends of the winding core portion, and project in directions perpendicular to an axial direction of the winding core portion. Concaves are positioned at corners formed of adjoining surfaces of the flanges that adjoin to the winding core portion and end surfaces of the flanges that are located at ends in a first perpendicular direction, which is one of the projecting directions of the flange. Connecting surfaces, which connect contact portions where the flanges contact with the winding core portion to the end surfaces, are at least part of inner peripheries of the concaves. All normal vectors of the connecting surfaces have components in the first perpendicular direction.