Coil Lead Wire Connector Structure for Wiring Board
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Solution Overview
Problem
Conventional electromagnetic coil devices face issues with the breakage of exposed conductor portions when mechanical loads are applied, leading to instability in the connection between lead wires and the wiring board.
Innovation Solution
The solution involves connecting the ends of lead wires to crimp terminals, which are then connected to the wiring board via a connector, eliminating the need for preliminary soldering and ensuring the connection remains stable under mechanical loads by using a resin-molded structure with a cover to secure the wiring board and lead wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the exposed conductor portion is directly soldered to the conductive pattern, then the connection is established, but the resiliency is lost and breakage occurs under load
Solution Approach 1:
A connector is introduced as an intermediary component between the lead wire and the wiring board. The connector includes a body that receives the lead wire and connection terminals that connect to the wiring board, eliminating direct soldering of the exposed conductor portion while maintaining stable electrical connection.
Solution Approach 2:
The connection system is divided into separate functional components: the lead wire, the connector body, and the connection terminals. This segmentation allows each component to perform its specific function optimally - the connector body protects the lead wire connection while the terminals provide reliable wiring board connection.
2Ease of manufacture
If preliminary soldering is performed on the exposed conductor portion, then electrical connection is achieved, but the portion hardens and loses resiliency
Solution Approach 1:
The connector serves as a mediator that eliminates the need for preliminary soldering of the exposed conductor portion. The lead wire is mechanically secured within the connector body through crimping or similar mechanisms, preserving the conductor's resiliency while achieving reliable electrical connection.
Solution Approach 2:
The soldering process is replaced with a mechanical connection mechanism within the connector body. The connection terminals provide mechanical and electrical connection to the wiring board without requiring the exposed conductor portion to undergo soldering, thus maintaining its mechanical properties.
3Device complexity
If the lead wire is directly connected to the wiring board, then the structure is simple, but the connection state is unstable under mechanical load
Solution Approach 1:
The connector acts as an intermediary structure between the lead wire and the wiring board. Although it adds a component, it significantly improves connection stability by providing a robust mechanical interface and protecting the lead wire connection points from mechanical stresses.
Solution Approach 2:
The connector body is designed to absorb and distribute mechanical loads before they reach the lead wire connection points. This beforehand cushioning prevents direct transmission of external forces to the delicate conductor portions, maintaining connection stability under load.
Data Source
Figure 1A~1E
Figure 2A~2C
Figure 3A~3F
AI summary
To prevent an exposed conductor portion from breaking and to maintain connection state between lead wires and a wiring board even when a load is added to the lead wires under the condition that the lead wires for a coil device is connected to and retained on the wiring board. In a structure for drawing out lead wires from a coil device according to the present invention, for drawing a lead wire from a terminal pin of a coil device 65 having a coil 62 and a plurality of terminal pins to which ends of the coil are connected, an end of the lead wire 2 is connected to a connector 1, the connector is connected at a side face thereof to a wiring board 67 for relay, and the wiring board is connected to the terminal pin. A connection terminal of the connector is connected to the wiring board in a direction perpendicular to a direction that the lead wire extends. In another case, after an end of the lead wire is connected a crimp terminal 3, the crimp terminal is connected at a side face thereof to a wiring board for relay, and thereafter the wiring board is connected to the terminal pin.