Wire Wound Inductor With Flush Surface Steps
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Solution Overview
Problem
The challenge is to reduce the size of wire wound inductor components while maintaining high frequency impedance characteristics, as thinner shaft portions compromise magnetic flux concentration and impedance characteristics.
Innovation Solution
A wire wound inductor component design featuring a columnar shaft portion with identical top and bottom surface steps of 50 μm or less, supported by rectangular plate-shaped support portions, and a cover member that reduces the outer dimensions, ensuring secure high frequency impedance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the shaft portion is made thinner to reduce the outer size of the component, then the size of the inductor component is reduced, but the high frequency impedance characteristics cannot be secured
Solution Approach 1:
The invention changes the geometric parameters of the core structure by making the top and bottom surfaces of the support portions substantially flush with the top and bottom surfaces of the shaft portion (top surface step and bottom surface step both ≤50 μm). This parameter change allows the shaft portion to maintain sufficient thickness for magnetic flux concentration while keeping the overall component size reduced, thereby preserving high frequency impedance characteristics.
2Ease of manufacture
If a bottom surface step is secured to accommodate terminal electrode mounting requirements, then the terminal electrode can be properly mounted, but the shaft portion becomes thinner compromising impedance characteristics
Solution Approach 1:
The invention changes the height parameter of the support portions relative to the shaft portion by minimizing the bottom surface step (≤50 μm). This allows the terminal electrodes to be mounted on the support portions while the shaft portion maintains sufficient thickness, resolving the contradiction between manufacturability and impedance characteristics.
Solution Approach 2:
The invention extends the support portions in the radial direction (width and depth) to provide sufficient mounting area for terminal electrodes, compensating for the reduced height dimension. This dimensional shift allows terminal electrode mounting without requiring a large bottom surface step, thereby preserving shaft portion thickness and impedance characteristics.
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 allows for size reduction while maintaining high frequency impedance characteristics and securing the strength of the shaft portion, enabling both size minimization and impedance preservation.
Implementation Method 1
a wire having a first end that is connected to the first terminal electrode and a second end that is connected to the second terminal electrode wound around the shaft portion
Data Source
AI summary
The wire wound inductor component includes a core including a columnar shaft portion extending in a first direction and first and second support portions at both end portions of the shaft portion, first and second terminal electrodes provided respectively on the first and second support portions, and a wire wound around the shaft portion. A distance between an upper surface of the shaft portion and a top surface of the first and second support portions in a second direction orthogonal to the first direction is defined as a top surface step, and a distance between a lower surface of the shaft portion and a bottom surface of the first and second support portions in the second direction is defined as a bottom surface step. The top and bottom surface steps are identical with each other, and the top and bottom surface steps are less than or equal to 50 μm.