Wound Coil Component Layout for Low-Profile Miniaturization
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Solution Overview
Problem
Conventional wound type coil components face challenges in miniaturization due to their lead frame structure, which limits their ability to achieve a low profile and secure a wide winding area for improved electrical characteristics.
Innovation Solution
The coil component design includes a body with a molded portion and a cover portion, featuring a wound coil embedded between these portions and accommodation grooves on the body's surface to house the coil ends, allowing for a compact and efficient flux area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional wound type coil structure with lead frame is used, then the coil component can be manufactured with basic electrical characteristics, but the component cannot be miniaturized and cannot achieve a low profile
Solution Approach 1:
The coil component is segmented into distinct functional regions: a winding region for the coil and a lead frame region for electrical connections. This segmentation allows the coil to be optimized for electrical characteristics while the lead frame is optimized for miniaturization and low profile, resolving the contradiction between size and electrical performance.
Solution Approach 2:
The lead frame is configured to extend in a direction substantially perpendicular to the coil winding plane, utilizing the vertical dimension to route electrical connections. This dimensional transition allows the lead frame to achieve a low profile while maintaining adequate winding area for the coil, simultaneously improving miniaturization without compromising electrical characteristics.
2Reliability
If the winding area is increased to improve electrical characteristics, then allowable current and DC resistance improve, but the component size increases and miniaturization is limited
Solution Approach 1:
Different regions of the component are assigned different functions and optimized locally: the winding region is designed with sufficient area for electrical characteristics, while the lead frame region is minimized for size. This local optimization allows the winding area to be adequate for electrical performance without requiring the entire component to be large, thus achieving miniaturization while maintaining electrical characteristics.
3Ease of manufacture
If the lead frame structure is used for basic manufacturing, then the component can be produced, but the structure prevents achieving a low profile and miniaturization
Solution Approach 1:
The lead frame is designed with flexible configuration options, allowing it to be bent and shaped to extend perpendicular to the coil plane. This dynamic configuration enables the lead frame to adapt to compact spatial requirements, achieving a low profile while maintaining manufacturing feasibility through standard lead frame fabrication and assembly processes.
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 enables the coil component to be lighter, thinner, shorter, and smaller while maintaining its electrical characteristics by securing the flux area, thus overcoming the miniaturization limitations of conventional coil components.
Implementation Method 1
a wound coil disposed between the molded portion and the cover portion and wound around the core
Data Source
AI summary
A coil component may include a body having one surface and the other surface facing each other, and including a molded portion having a core and a cover portion disposed on the molded portion; a wound coil disposed between the molded portion and the cover portion and wound around the core; and a first accommodation groove and a second accommodation groove disposed on the one surface of the body to be spaced apart from each other, and respectively disposed outside of a region of the body corresponding to the core, wherein both end portions of the wound coil are respectively disposed in the first and second accommodation grooves, and a minimum value of a distance between the first and second accommodation grooves is greater than a diameter of the core.