Coil Lead-Out Joint Structure for Higher Core Volume
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing coil devices with wire connections inside the core face issues with reduced core volume due to molten beads from welding, leading to deteriorated inductance characteristics.
Innovation Solution
A coil device design featuring a lead-out portion with a joint portion of smaller thickness and a non-joint portion, where the joint portion is compressed to increase core volume and improve inductance, and a wire connection portion with a metal layer for enhanced stability, along with a method of pressure-joining the lead-out portion to the terminal and embedding it within a core made of magnetic material and resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire connection portion is disposed inside the core and welded to the terminal, then the wire connection portion is protected from contact with other components, but molten beads are formed around the welded portion which reduces the volume of the core and deteriorates the inductance characteristics
Solution Approach 1:
The lead-out portion is divided into a joint portion (with smaller first thickness) and a non-joint portion (with larger second thickness). This segmentation allows the joint portion to be compactly joined to the wire connection portion inside the core, minimizing the space occupied by the joint while maintaining structural integrity. The non-joint portion maintains the original thickness for mechanical strength, thus preserving core volume and inductance characteristics while still protecting the wire connection portion.
2Volume of stationary object
If the joint portion is made with smaller thickness to increase core volume, then the inductance characteristics are improved, but the physical strength of the wire connection portion may be reduced
Solution Approach 1:
Different portions of the lead-out portion have different thickness characteristics: the joint portion has a smaller first thickness for compact joining and maximizing core volume, while the non-joint portion has a larger second thickness for maintaining physical strength. This local differentiation of quality allows each portion to optimize its function - the joint portion minimizes space occupation inside the core, while the non-joint portion provides mechanical strength support.
3Volume of stationary object
If the first thickness of the joint portion is smaller than the second thickness of the non-joint portion, then the core volume is increased and inductance characteristics are improved, but the manufacturing complexity increases
Solution Approach 1:
The thickness parameter of the lead-out portion is changed along its length, with the joint portion having a smaller first thickness and the non-joint portion having a larger second thickness. This parameter change is achieved through controlled deformation or selective material removal during the manufacturing process, allowing the joint portion to be compactly formed for maximum core volume while maintaining the overall structural integrity and manufacturability of the component.
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 the inductance characteristics and physical strength of the coil device by increasing the core volume and stability of the joint, while maintaining protection from external components.
Implementation Method 1
the joint portion is in the state of being compressed in a thickness direction, so that the joint portion can be compactly joined to the wire connection portion
Implementation Method 2
pressure-joining the lead-out portion to the terminal
Data Source
AI summary
A coil device includes: a core; a coil including a winding portion disposed inside the core, and a lead-out portion led out from the winding portion; and a terminal including a wire connection portion joined to the lead-out portion and disposed inside the core. The lead-out portion includes a joint portion joined to the wire connection portion, and a non-joint portion separated from the joint portion. A first thickness of the joint portion is smaller than a second thickness of the non-joint portion.