Coil Component Manufacturing Jig for Resin Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing coil components with resin-sealed portions face challenges such as unnecessary waste and increased costs due to the need for special wire-winding machines and complex handling processes, especially when cutting off semi-finished products from a plate-shaped mother metal portion.
Innovation Solution
A method involving a jig that holds and positions semi-finished products with a metal-made lead frame, allowing for easier handling and resin sealing using a mold, which reduces waste and eliminates the need for special wire-winding machines by allowing coil formation before cutting the products from the plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If semi-finished products are cut off from the plate before wire-winding, then wire-winding becomes easier to carry out, but handling time and complexity increase due to individual processing requirements
Solution Approach 1:
The patent applies preliminary action by performing wire-winding on the plate-shaped mother metal portion before the cutting-off process. The coil is formed by winding wire around rod-shaped cores that are still attached to the plate, allowing subsequent cutting to separate the finished coil components from the plate without affecting the already-formed coils.
2Ease of operation
If semi-finished products are not cut off before wire-winding, then handling is simpler, but special wire-winding machines with rotating mechanisms are required and space between cores must be widened
Solution Approach 1:
The patent performs the wire-winding operation preliminarily while the rod-shaped cores are still mounted on the plate-shaped mother metal portion. This preliminary action eliminates the need for special rotating wire-winding machines, as the plate itself provides stable support during the winding process, and standard wire-winding equipment can be used.
3Ease of operation
If many semi-finished products are processed individually, then wire-winding is easier, but productivity decreases due to repeated handling and setup
Solution Approach 1:
The patent merges multiple semi-finished products onto a single plate-shaped mother metal portion, allowing wire-winding to be performed on multiple rod-shaped cores simultaneously or in sequence without removing them from the plate. This combining approach maintains operational simplicity while significantly improving productivity by processing multiple components in one setup.
Solution Approach 2:
The plate serves as a preliminary mounting structure that holds multiple rod-shaped cores in position before wire-winding. This preliminary arrangement enables efficient batch processing, where all cores are prepared and positioned on the plate before the wire-winding operation begins, reducing repeated handling and setup time.
4Ease of operation
If space between adjacent rod-shaped cores is widened, then wire-winding can be carried out without cutting, but the amount of wasted plate material increases
Solution Approach 1:
The patent performs wire-winding as a preliminary operation before cutting the plate. This allows the use of minimal spacing between rod-shaped cores during the winding process, as the plate provides structural support. After wire-winding is complete, the plate is cut to separate the individual coil components, maximizing plate utilization and minimizing waste.
Data Source
AI summary
A manufacturing method of a coil component including the steps of: holding a plurality of semi-finished products, each of which includes a base and a coil before forming the coil component, with a jig having a holding portion; setting the plurality of semi-finished products held by the jig to the setting positions of the jig in a mold; and sealing at least a portion within the base and the coil with resin by filling the resin into a cavity of the mold.