Coil Structure With FPCB Terminals and Coating-Stabilized Windings
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Solution Overview
Problem
Conventional coil structures in wireless transmitters face issues with terminal parts of metal wires not being easily positioned for soldering, leading to loose winding turns and instability during the soldering process.
Innovation Solution
A coating layer is applied to encapsulate the terminal parts and winding turns of the coil, ensuring stable positioning and connection with external circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal part of the metal wire is exposed from the insulating layer for electrical connection, then electrical connectivity is achieved, but the terminal part cannot be positioned firmly during soldering
Solution Approach 1:
The patent divides the wire structure into distinct segments: the metal wire core, the insulating layer, and the exposed terminal part. This segmentation allows the terminal part to be specifically designed for soldering while the rest of the wire maintains its insulating properties, resolving the contradiction between electrical connectivity and positioning stability.
Solution Approach 2:
The patent introduces an intermediary structure (the exposed terminal part of the metal wire) that mediates between the insulating layer and the external circuit. This intermediary enables electrical connection while providing a dedicated surface for soldering, thus resolving the positioning difficulty without compromising insulation.
2Reliability
If the coil undergoes soldering process with exposed terminal parts, then electrical connection is established, but the winding turns become loose and relative positions change
Solution Approach 1:
The patent applies preliminary action by pre-positioning and securing the winding turns before the soldering process. The coil structure is designed with features that maintain the relative positions of winding turns, preventing them from becoming loose during subsequent soldering operations.
Solution Approach 2:
The patent utilizes parameter changes in the material properties, specifically employing materials with appropriate melting points and bonding characteristics that allow the winding turns to be securely held during the thermal soldering process without deforming or shifting positions.
Data Source
AI summary
A coil structure comprises a coil formed by a conductive wire and a flexible printed circuit board, wherein the flexible printed circuit board is disposed across a plurality winding turns of the coil, wherein a first terminal part and a second terminal part of the conductive wire are respectively electrically connected to the flexible printed circuit board for electrically connecting to an external circuit.