Coil Component Manufacturing Local Heating Adhesive Curing
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Solution Overview
Problem
The existing method for manufacturing coil components, such as common-mode choke coils, faces inefficiencies in heating the adhesive due to the large thermal capacity of jigs, leading to prolonged heating times and difficulty in finely controlling temperatures, which affects the curing process.
Innovation Solution
A method and apparatus that locally heats the metal terminals using a pressing member with a contact surface, allowing for efficient curing of the adhesive without the need for a large jig, where the pressing member, potentially a heater chip, applies heat directly to the adhesive, and includes a grinding step to ensure cleanliness and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is used to fix the core and metal terminals for heating in an oven, then positional accuracy is improved, but heating time increases and temperature control becomes difficult
Solution Approach 1:
The heating process is segmented into two distinct stages: first, the adhesive is cured by heating only the metal terminals and core without the jig; second, the jig is attached for positional fixing. This segmentation allows the adhesive to cure efficiently before the jig's thermal mass slows down the process, resolving the contradiction between positional accuracy and heating time.
Solution Approach 2:
The adhesive curing process is performed as a preliminary action before attaching the jig for final positional fixing. By curing the adhesive first while the components are still free of the jig's thermal mass, the process achieves both efficient heating and subsequent positional accuracy through the jig's support during the second stage.
2Manufacturing precision
If a jig with large thermal capacity is heated in the oven, then the core and metal terminals are fixed in position, but the adhesive cannot be efficiently heated
Solution Approach 1:
The process separates the heating function from the positional fixing function by performing adhesive curing before attaching the jig. This segmentation ensures that the jig's large thermal capacity does not interfere with efficient adhesive heating, while still providing positional accuracy in the subsequent stage.
Solution Approach 2:
Instead of heating the entire assembly including the jig, the process applies heat only to the necessary components (metal terminals and core) for adhesive curing. This partial heating approach avoids the thermal mass problem of the jig while achieving sufficient temperature for adhesive curing.
3Manufacturing precision
If the jig is attached to the core and metal terminals before heating, then positional accuracy is maintained, but the heating process becomes inefficient
Solution Approach 1:
The manufacturing process is segmented into distinct operations: adhesive application, heating for curing without jig, and then jig attachment for positional fixing. This segmentation eliminates the inefficiency of heating the jig while maintaining positional accuracy in the final stages, thereby improving overall productivity.
Solution Approach 2:
The adhesive curing heating is performed as a preliminary action before the jig is attached. This preliminary heating step completes the adhesive bonding process efficiently, after which the jig is attached for positional accuracy without interfering with the already-cured adhesive, thus improving manufacturing efficiency.
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 approach enables efficient heating and curing of the adhesive with improved temperature control and reduced misalignment, enhancing the manufacturing process by applying heat directly to the bonding area and preventing foreign substances from interfering with the process.
Implementation Method 1
a heating step of locally heating the metal terminal while the metal terminal is supported by a pressing member having a contact surface capable of coming into contact with the metal terminal
Data Source
AI summary
A method of manufacturing a coil component includes a heating step of locally heating metal terminals while the metal terminals are supported by a pressing member having a contact surface capable of coming into contact with the metal terminals in a state where an adhesive is disposed between the metal terminals and a drum core.