Coil Component Lead Wire Orthogonal Exit

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional coil components face challenges in ensuring positional accuracy and reliability, especially during miniaturization, due to lead wires being drawn out in different directions, requiring bending and complex welding processes, which complicates the manufacturing process and can lead to connectivity issues.

Innovation Solution

A coil component design where lead wires are drawn out orthogonally to the coil axis in the same direction, eliminating the need for bending and allowing for stable welding within the component's dimensions, using a terminal fitting with a welding piece that has higher wettability than the rear surface to secure the welding portion, and a method involving pressing and welding the lead wire and terminal fitting to ensure secure connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If lead wires are drawn out in different directions (180 degrees apart) from the coil, then the coil component can be manufactured using conventional methods, but it becomes difficult to ensure positional accuracy of the lead wires and requires bending operations that complicate the manufacturing process

Engineering Contradiction:

Improvepositional accuracy of lead wireVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of drawing lead wires in opposite directions (180 degrees apart) as in conventional designs, this invention draws both lead wires in the same direction (parallel arrangement). This inversion of the conventional lead wire arrangement eliminates the need for bending operations and significantly improves positional accuracy while simplifying the manufacturing process.

Inventive Principle:

Principle #13The other way round (Inversion)

2Volume of moving object

If the diameter of the lead wire is reduced for miniaturization, then the coil component size is reduced, but it becomes difficult to maintain the lead wire in a bent shape and ensures reliable welding

Engineering Contradiction:

Improvesize of coil componentVSAvoidreliability of welding and lead wire maintenance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

By inverting the conventional lead wire arrangement from opposite directions to parallel directions, the invention eliminates bending requirements. This allows miniaturization to proceed without compromising welding reliability, as straight lead wires of smaller diameter can be reliably welded to the terminal fitting without the structural weaknesses introduced by bending operations.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If conventional manufacturing methods are used requiring winding and bending steps, then the process can accommodate traditional designs, but work efficiency is reduced due to multiple complex steps

Engineering Contradiction:

Improvework efficiency in manufacturingVSAvoidease of manufacturing process

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention inverts the conventional manufacturing approach by arranging lead wires to exit in the same direction, which eliminates the need for bending and winding steps. This simplification directly improves work efficiency and makes the manufacturing process easier to execute with fewer operational complexities.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts and eliminates the bending and winding steps from the manufacturing process by redesigning the lead wire arrangement. By removing these unnecessary intermediate steps through the parallel lead wire configuration, the manufacturing process becomes more efficient and easier to execute.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enhances positional accuracy and reliability, simplifies the manufacturing process, and improves work efficiency by eliminating the need for complex bending and ensuring stable welding, even during miniaturization, while preventing heat transfer and interference with other components.

Implementation Method 1

a welding piece (42) extending along the lead wire (3) and welded with the lead wire (3), the welding piece (42) including a welding surface (42a) to be in contact with the lead wire (3), the welding surface (42a) having higher wettability than a rear surface (42b) of the welding surface (42a)

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS8264316B2Coil component and method for manufacturing coil component

Publication Date: 2012.09.11 TDK CORP

AI summary

To provide a coil component that can adequately ensure component accuracy even when miniaturization is pursued. A coil component includes a main body portion structured with green compact containing magnetic material, a coil arranged inside the main body portion, a pair of lead wires each drawn out from the coil to outside of the main body portion, terminal fittings electrically connected to the lead wires at the outside of the main body portion, and welding portions connecting the lead wires and the terminal fittings. The pair of lead wires is both drawn out towards a first direction that is orthogonal to an axis direction of the coil. Drawing surfaces of the main body portion are disposed towards the coil side from a first side surface that is an end of the main body portion in the first direction. The drawing surfaces perpendicularly intersect the lead wires.