Coil Assembly Coating for Stable Terminal Soldering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coil structures in wireless transmitters face challenges in maintaining the stability and performance of winding turns during soldering processes, as the terminal parts of the metal wire can become loose, and positioning issues arise during electrical connections.
Innovation Solution
A coating layer is formed to encapsulate the terminal parts and winding turns of the coil, using materials like resin, silicone, or plastic, to stabilize the structure and facilitate automatic soldering processes, ensuring secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal part of the metal wire is exposed from the insulating layer for electrical connection, then electrical connection is enabled, but the terminal part cannot be positioned firmly during soldering process
Solution Approach 1:
The coating layer is formed on the insulating layer before the soldering process, preliminarily establishing a positioning structure that will guide and secure the terminal part during subsequent soldering operations. This preliminary action prevents positioning issues before they occur.
Solution Approach 2:
The coating layer acts as an intermediary between the insulating layer and the external environment, providing a surface that facilitates both electrical connection and firm positioning during soldering. It mediates between the need for wire exposure and the need for stable positioning.
2Ease of operation
If the coil undergoes soldering process for electrical connection, then electrical connection is achieved, but the winding turns become loose and relative positions change
Solution Approach 1:
The coating layer is applied to the insulating layer before soldering, preliminarily securing the winding turns in their correct relative positions. This prevents the turns from becoming loose during the soldering process.
Solution Approach 2:
The coating layer provides beforehand cushioning protection to the winding turns, acting as a stabilizing structure that prevents displacement and loosening during the thermal and mechanical stresses of the soldering process.
3Manufacturing precision
If a coating layer is formed to encapsulate the terminal part and winding turns, then positioning stability and structure rigidity are improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The coating layer combines multiple functions into a single structure: it provides positioning stability, protects the insulating layer, and maintains the rigidity of the terminal part. This merging reduces the need for separate components and simplifies the overall manufacturing process.
Solution Approach 2:
The coating layer serves multiple purposes simultaneously: it acts as a positioning structure, a protective layer, and a rigidity-enhancing element. This multi-functionality reduces the number of separate manufacturing steps and components needed.
Data Source
AI summary
A coating layer is formed on a coil made of an insulated conductive wire comprising a metal wire and an insulating layer encapsulating the metal layer, wherein the coating layer encapsulates at least one portion of the insulating layer of the insulated conductive wire so that a terminal part of the metal wire exposed from the insulating layer can be positioned firmly while going through an automatic soldering process for electrically connecting with an external circuit.