Coil Component Laser Welding Insulation Edge Control
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Solution Overview
Problem
Conventional coil components face challenges in achieving a satisfactory electrical connection between terminal electrodes and conducting wires, particularly due to inadequate insulation coating removal and connection stability.
Innovation Solution
The coil component design includes a core with mounting portions on a circuit board, terminal electrodes with a bulge portion for contact with the insulation coating edge, and pulsed laser welding to ensure secure electrical connections, maintaining the insulation coverage for stability and preventing excessive welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation coating is completely removed for welding, then electrical connection is improved, but the conducting wire becomes vulnerable to damage and manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by selectively removing insulation coating only at the specific welding location rather than completely stripping the entire conducting wire. This localized approach ensures reliable electrical connection at the connection point while preserving insulation coverage on the rest of the wire, preventing damage and simplifying the manufacturing process.
2Reliability
If more insulation coating is removed to ensure connection, then electrical connection is improved, but the risk of conducting wire deformation and excessive melting increases
Solution Approach 1:
The patent applies preliminary action by pre-forming a groove structure on the terminal electrode surface before the welding process. This groove acts as a physical guide and constraint that limits the welding arc's interaction with the conducting wire, preventing excessive melting and deformation even when insulation coating is removed for connection.
3Reliability
If insulation coating is removed at connection point, then electrical connection is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies self-service by designing the terminal electrode with an integrated groove structure that automatically guides the welding process. The groove's geometry self-regulates the welding arc placement and duration, reducing the need for high-precision manual insulation removal and minimizing the risk of excessive melting or deformation.
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 achieves stable and improved electrical connections, reducing manufacturing costs and assembly errors while maintaining the quality of the common mode filter by ensuring only the necessary insulation is stripped and welded, thus preventing deformation and excessive melting.
Implementation Method 1
Each terminal electrode has a welded portion at which each of the end portions of the at least one conducting wire is electrically connected to each of the terminal electrodes upon welding
Implementation Method 2
Each welded portion has a bulge portion bulging in a direction away from the core and in contact with only the distal edge of the insulation coating
Data Source
AI summary
Each terminal electrode has a welded portion at which each end portion of a conducting wire is electrically connected to each terminal electrode upon laser welding. The conducting wire is provided with an insulation coating. The insulation layer has an edge on the surface of the conducting wire. Each welded portion has a bulge portion bulging in a direction away from the core and in contact with only the edge of the insulation coating. The edge determines a shape position and size of a melted bulge portion.