Actuator Coil Lead Structure for Wire Disconnection Prevention
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Solution Overview
Problem
Existing actuators with magnetic drive mechanisms are prone to coil wire disconnection due to tensile forces applied by external impacts or thermal changes, as the lead parts of the coil wire can become disconnected from the power feeding circuit board.
Innovation Solution
The actuator design incorporates a resiliently bent portion for the lead part of the coil wire, which is extended from the winding part to a land on the board via a recessed part, and an adhesive layer that fixes the coil to the coil holder without covering the resiliently bent portion, allowing it to move freely and prevent disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead part is extended in a straight line shape between the winding part and the power feeding circuit board, then the structure is simple and easy to manufacture, but tensile force applied during impact or thermal change causes disconnection
Solution Approach 1:
The lead part is designed with a curved shape instead of a straight line, extending from the winding part along the inner circumference of the coil and then to the power feeding circuit board. This curvature allows the lead part to flex and absorb tensile forces during impact or thermal changes, preventing disconnection while maintaining manufacturing simplicity
Solution Approach 2:
The lead part's physical configuration is changed from a straight line to a curved path that follows the coil's inner circumference. This parameter change in geometry enables the lead part to accommodate thermal expansion and impact forces, improving reliability without significantly complicating the manufacturing process
2Strength
If adhesive layer is applied to fix the coil to the coil holder, then the coil is securely held, but the resiliently bent portion may be covered and restricted from moving freely
Solution Approach 1:
The adhesive layer is applied selectively only to specific regions of the coil holder where it is needed for structural support, while deliberately avoiding the area where the resiliently bent portion is located. This local differentiation allows the adhesive to provide strong fixation where required while leaving the resilient portion free to move and absorb shocks
Solution Approach 2:
The coil holder structure is segmented into different functional zones: one zone with adhesive application for secure mounting, and another zone without adhesive to accommodate the resiliently bent portion. This segmentation allows both strong fixation and flexible movement to coexist in the same assembly
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 effectively prevents coil wire disconnection by allowing the resiliently bent portion to elongate under tensile force, keeping the lead part connected and reducing the risk of excessive load on the soldered tip end, thus enhancing the actuator's durability and reliability.
Implementation Method 1
the resiliently bent portion is extended and elongated and thus, the lead part is prevented from becoming a state being pulled between the board and the winding part
Data Source
AI summary
An actuator comprises a support body including a coil having a winding part and a lead part, a coil holder and a board supported by the coil holder, a movable body having a magnet, and a magnetic drive mechanism structured to relatively move the support body and the movable body. The coil holder has a coil holding part holding the winding part and a board support part supporting the board. A board surface of the board is provided with a land with which the lead part is connected. The board support part has a recessed part at a position overlapping with the board when viewed in a direction along the board surface, and the lead part is extended from the winding part to the land via the recessed part and is provided with a resiliently bent portion which is resiliently bent in an inside of the recessed part.