Wound Coil Layout With Offset End Grooves for Miniaturization
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Solution Overview
Problem
Conventional wound type coil components face limitations in miniaturization due to their structural constraints, which hinder the achievement of a wider winding area necessary for improved electrical characteristics and space-efficient design in limited spaces.
Innovation Solution
A coil component design featuring a body with a molded portion and a cover portion, incorporating a wound coil and accommodation grooves that allow the coil ends to be disposed outside the core region, with the minimum distance between grooves greater than the core's dimension, enabling a lighter, thinner, and smaller form factor while maintaining magnetic flux area and electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional wound type coil component structure is used, then the coil component can be manufactured with a simple structure, but the coil component cannot be miniaturized due to structural constraints of the lead frame
Solution Approach 1:
The coil component is divided 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 positioned independently in the winding region, enabling miniaturization while the lead frame handles external connections, thus resolving the structural constraints that previously prevented size reduction.
Solution Approach 2:
The patent repositions the coil ends to extend in a direction substantially perpendicular to the winding plane, utilizing the vertical dimension rather than only the horizontal plane. This dimensional change allows the coil to achieve its electrical characteristics without requiring a large planar area, enabling miniaturization of the overall component footprint.
2Reliability
If the winding area is increased to improve electrical characteristics, then the allowable current and DC resistance improve, but the coil component size increases
Solution Approach 1:
The patent concentrates the magnetic flux density in specific regions by positioning the coil in a dedicated winding region with optimized geometry. The core structure is designed to concentrate magnetic flux where needed, allowing high electrical characteristics to be achieved in a localized area rather than requiring a uniformly large winding area throughout the component.
Solution Approach 2:
By extending coil ends perpendicular to the winding plane and utilizing vertical space for lead frame connections, the patent enables a compact planar footprint while maintaining sufficient winding area. The multi-layer coil structure also utilizes the vertical dimension to increase effective winding area without increasing the component's planar dimensions.
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 the miniaturization of coil components while securing the magnetic flux area, improving inductance and electrical characteristics without increasing the overall thickness, thus addressing the 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.