Coil Component Laser Welding Insulation Control
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Solution Overview
Problem
Existing coil components face issues with excessive welding on terminal electrodes, leading to deformation and unsatisfactory connections, which degrade the performance of components like common mode filters.
Innovation Solution
A coil component design featuring terminal electrodes with a bulge portion that bulges away from the core, where an insulating layer is positioned between the end of the conducting wire and the foundation, allowing for controlled laser welding to prevent excessive melting and deformation, ensuring a stable and satisfactory connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed to connect the conducting wire to the terminal electrode without peeling the insulation layer, then the connection is achieved, but excessive welding occurs on the terminal electrode causing deformation
Solution Approach 1:
The insulating layer is pre-positioned on the terminal electrode at the connection location before the welding process. This preliminary action prevents excessive welding by blocking the welding heat from penetrating too deeply into the terminal electrode, thereby avoiding deformation while still allowing the conducting wire to be welded to the electrode surface.
Solution Approach 2:
The insulating layer acts as an intermediary substance between the conducting wire and the terminal electrode during welding. It mediates the welding process by controlling heat distribution, allowing sufficient heat for connection while preventing excessive heat that would cause deformation of the terminal electrode.
2Shape
If the insulating layer is positioned in the bulge portion during welding, then excessive welding is prevented, but the manufacturing process complexity increases
Solution Approach 1:
The insulating layer is integrated with the terminal electrode structure by positioning it within the bulge portion during the molding process. This merging of the insulating layer with the electrode formation process eliminates the need for separate insulating layer installation steps, thereby preventing deformation without significantly increasing manufacturing complexity.
Solution Approach 2:
The bulge portion of the terminal electrode is designed with specific dimensional parameters that accommodate the insulating layer. By controlling the size and shape parameters of the bulge portion, the insulating layer is automatically positioned correctly during molding, simplifying the overall manufacturing process while preventing excessive welding.
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 stabilizes the connection state, prevents excessive welding and deformation of terminal electrodes, and maintains the quality of the common mode filter, while also reducing manufacturing costs by minimizing the number of parts and steps involved.
Implementation Method 1
The insulating layer is provided in the bulge portion at a position between the end portion and the foundation portion... preventing excessive welding and deformation
Implementation Method 2
each end portion of each conducting wire is welded to each terminal electrode... End portion of the conductive wire, the insulation layer, and a part of the terminal electrode are melted together to form a welded part
Data Source
AI summary
A coil component including a connection part not excessively welded to a terminal electrode. End portion of a conducting wire of a common mode filter is laser-welded, while being held by a holding piece and a surface of the terminal electrode. A portion melted by laser-welding includes a bulge portion which bulges in a direction away from a core. There is provided a lower insulation covering portion between a foundation and the portion corresponding to the end portion of the conducting wire. For the bulge portion, the lower insulation covering portion is provided only between the foundation and the portion corresponding to the end portion of the conducting wire, thereby preventing excessive welding to a terminal electrode.