Wire-Wound Inductor Core Structure for Low-Height Cover Bonding
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Solution Overview
Problem
Existing wire-wound inductor components face challenges in miniaturization due to fixed height and size constraints, particularly in achieving a reduction in height and size while maintaining functionality, as the existing manufacturing methods and designs limit the reduction of the core's dimensions and lead to difficulties in molding and application of cover members.
Innovation Solution
A wire-wound inductor component design with a core having a smaller top surface step compared to the bottom surface step, where the top surface step is larger than the wire diameter and the distance between the shaft portion's upper surface and the wire's uppermost surface is greater than half of the top surface step, allowing for independent adjustment of steps and reducing the height and size of the component while ensuring adequate spacing and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the bottom surface step is increased to accommodate terminal electrode height and spacing requirements, then the terminal electrode can be properly formed and positioned, but the overall height of the core increases
Solution Approach 1:
The core is designed with asymmetric step structures where the top surface step (first step) is smaller than the bottom surface step (second step). This asymmetry allows the bottom surface to provide sufficient space for terminal electrode formation and spacing, while the top surface maintains a compact profile suitable for miniaturization and cover member application.
2Ease of manufacture
If the top surface step is increased to match the bottom surface step for uniform manufacturing, then the core can be molded with uniform pressure, but the space for cover member application becomes too narrow and deep
Solution Approach 1:
The core is designed with asymmetric step structures where the top surface step (first step) is smaller than the bottom surface step (second step). This asymmetry allows the bottom surface to provide sufficient space for terminal electrode formation and spacing, while the top surface maintains a compact profile suitable for miniaturization and cover member application.
3Volume of moving object
If the core is miniaturized to reduce overall size, then the component becomes more compact, but the space between the shaft portion and cover member becomes too narrow
Solution Approach 1:
The core is designed with asymmetric step structures where the top surface step (first step) is smaller than the bottom surface step (second step). This asymmetry allows the bottom surface to provide sufficient space for terminal electrode formation and spacing, while the top surface maintains a compact profile suitable for miniaturization and cover member application.
Solution Approach 2:
Different regions of the core have different step dimensions optimized for their specific functions: the bottom surface has a larger step for terminal electrode requirements, while the top surface has a smaller step for cover member application and miniaturization.
Data Source
AI summary
A wire-wound inductor component includes a core having a columnar shaft portion, first and second support portions provided on first and second end portions of the shaft portion, first and second terminal electrodes provided on the respective support portions, a wire wound around the shaft portion, and a cover member covering an upper surface of the shaft portion. In a height direction of the core, a distance between an upper surface and a top surface of the support portions is a top surface step, and a distance between a lower surface of the shaft portion and a bottom surface of the support portions is a bottom surface step. The top surface step is smaller than the bottom surface step and larger than a wire diameter, and a distance between the upper surface and an uppermost surface of the wire is larger than half of the top surface step.