Coil Device With Inclined Electrode Fixing Surfaces
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Solution Overview
Problem
Conventional coil devices face issues with surface mounting uniformity and production variation due to the formation of alloy layers that deteriorate solder wettability, and inaccuracies in wire cutting positions, leading to poor wettability and size accuracy.
Innovation Solution
The coil device features a magnetic core with inclined fixing surfaces on the electrode parts, which control the wire cutting position accurately and prevent alloy layer formation on unwanted areas, ensuring good solder wettability and surface mounting properties. Additionally, the use of metal terminal fittings with inclined tips and non-fixing surfaces aids in precise cutting and reduces production variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional wire cutting methods are used, then production speed is maintained, but wire cutting position varies and alloy layer forms on terminal surface
Solution Approach 1:
The inclined fixing surface is prepared in advance on the electrode part, which guides the wire to a predetermined cutting position before the cutting operation occurs. This preliminary structural arrangement ensures accurate wire cutting position without requiring complex real-time control during production, thus maintaining both precision and productivity
2Productivity
If heating method is used for wire cutting, then cutting speed increases, but alloy layer extends to terminal surface
Solution Approach 1:
The inclined fixing surface creates a localized geometry where the wire is guided to a specific cutting zone. This local structural feature ensures that even when heating is applied for fast cutting, the alloy layer forms only in the inclined region and does not extend to the flat terminal surface, thus maintaining good wettability while achieving high cutting speed
3Object-generated harmful factors
If multiple surfaces with steps are formed at terminals, then alloy layer formation is reduced, but device complexity increases
Solution Approach 1:
Instead of creating multiple flat surfaces with steps, the invention uses a single inclined asymmetric surface. This asymmetric geometry naturally guides the wire to a predetermined position and prevents alloy layer extension to the terminal surface, achieving the same protective effect with simpler single-surface structure rather than complex multi-surface steps
Data Source
AI summary
The coil device comprises the magnetic core comprising the axial part and the magnetic core end part connecting to the axial part, the coil part formed by winding the wire around the axial part, and the electrode part provided at the magnetic core end part and made of good conductor. Said electrode part comprises the fixing surface fixed with a wire end part of said wire, and the fixing surface is provided on a side surface which does not intersect with a center axis of said coil part at said magnetic core end part. Said fixing surface is inclined to a direction, away from said center axis with respect to a direction towards said magnetic core end part from said axial part.