Choke Coil Wire Fixation via Accommodation Grooves
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Solution Overview
Problem
Choke coils face issues with shape deformation and positional misalignment of wires due to pressing forces, leading to unreliable attachment and varying quality in manufacturing.
Innovation Solution
Incorporating wire accommodation parts on terminal electrodes, which accommodate at least a portion of the wire, minimizing shape deformation and ensuring proper positioning through grooves and protrusions, and using laser welding to form weld parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the extension parts press the wires to fix them, then the wires are fixed to the terminal electrodes, but the wires are crushed and their original circular shapes are changed
Solution Approach 1:
The terminal electrode is segmented into a pressing part and an extension part, with the pressing part having a pressing surface that contacts the wire and the extension part extending from the pressing part. This segmentation allows the pressing force to be applied in a controlled manner that secures the wire without excessive crushing.
Solution Approach 2:
The pressing surface of the pressing part is designed with specific local properties (flat surface configuration) to distribute the pressing force evenly across the wire contact area. This local quality optimization ensures adequate fixation while minimizing wire deformation.
2Reliability
If the extension parts press the wires with sufficient force to prevent loosening, then the wires are securely fixed, but the wires are weakened by the pressing force and may be cut during operation
Solution Approach 1:
The extension part is designed to be bendable, allowing it to dynamically adapt to the wire position while applying appropriate pressing force. The bending capability enables the extension part to exert securing force without excessive compression that would weaken the wire.
Solution Approach 2:
The pressing force parameter is optimized by designing the extension part's geometry and material properties to provide sufficient fixation force while remaining below the threshold that would cause wire weakening or failure.
3Reliability
If the wires are pressed by the extension parts, then the wires are fixed to the terminal electrodes, but the wires are pushed or deviate from their initial positions causing positional deviation
Solution Approach 1:
The wire is positioned and fixed to the pressing part before the extension part is bent into its final position. This preliminary action ensures the wire is securely attached to a stable reference point before any pressing or positioning adjustments are made by the extension part.
Solution Approach 2:
The extension part is designed to bend in a direction perpendicular to the wire axis, allowing it to apply securing force without pushing the wire laterally. This dimensional separation of the bending action from the wire positioning prevents positional deviation.
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 solution enhances the tensile force of the wires, improves resistance to shock and vibration, and ensures consistent product quality by maintaining wire position during the welding process.
Implementation Method 1
weld parts are formed on upper portions of the terminal electrodes by using laser welding or arc welding
Implementation Method 2
weld parts are formed on upper portions of the terminal electrodes by using laser welding or arc welding
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The present disclosure provides a choke coil including a core, a flange provided on each of both end portions of the core in one direction, a terminal electrode coupled to the flange, a wire wound around the core and having end portions each led out to the terminal electrode, and a wire accommodation part configured to accommodate each of the end portions of the wire.