Electromagnetic Driver Coil Lead-out Structure
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Solution Overview
Problem
The manual soldering process in manufacturing electromagnetic drivers, such as voice coil motors, is cumbersome and inefficient, especially in compact devices like mobile phones and cameras, making automatic manufacturing and maintenance difficult.
Innovation Solution
An electromagnetic driver with a coil holder featuring metal connecting members that allow for automatic assembly and connection of lead-out wires to conductive terminals, eliminating the need for manual soldering and enabling easier replacement and recycling of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used to connect coil lead-out wires to conductive members, then reliable electrical connection is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent divides the coil assembly into separate modules: the coil wound on the coil holder forms one module, and the conductive member (spring) forms another module. The metal connecting member acts as an intermediate connector between these modules. This segmentation allows each module to be manufactured and tested independently, then assembled together through simple connection operations rather than complex soldering processes.
Solution Approach 2:
The patent introduces a metal connecting member as an intermediary component between the coil lead-out wires and the conductive member (spring). This intermediary element simplifies the connection process by providing a standardized interface that can be connected through simple mechanical means (such as insertion or clipping) rather than requiring soldering, thus reducing manufacturing complexity while maintaining reliable electrical connection.
2Reliability
If manual soldering is used for coil wire connection, then reliable electrical connection is achieved, but productivity decreases due to manual labor requirement
Solution Approach 1:
By segmenting the assembly into pre-manufactured modules (coil assembly with metal connecting member, and separate conductive member), the patent enables automated assembly lines to simply pick and place these modules together without requiring manual soldering operations, thereby significantly improving productivity while maintaining connection reliability through the standardized metal connecting member interface.
Solution Approach 2:
The metal connecting member is designed to enable self-aligning and self-securing connections between the coil assembly and conductive member, potentially through features like elastic retention or snap-fit mechanisms. This self-service capability eliminates the need for manual dexterity in soldering operations, allowing automated equipment to perform the assembly and thereby increasing productivity.
3Volume of moving object
If compact electromagnetic drivers are used in mobile phones and cameras, then device size is reduced, but manufacturing difficulty increases due to limited space for manual operations
Solution Approach 1:
The patent segments the electromagnetic driver into compact, pre-assembled modules (coil holder with coil and metal connecting member as one module, spring as another module). This modular segmentation allows each module to be optimized and manufactured separately, then quickly assembled together, making it feasible to manufacture compact drivers for mobile phones and cameras without requiring complex manual operations in tight spaces.
Solution Approach 2:
The metal connecting member serves as a compact intermediary that enables reliable electrical connection in a space-efficient manner. Its design allows for simple mechanical connection rather than requiring manual soldering operations, making the assembly process easier and more suitable for compact device manufacturing where space for manual operations is limited.
4Device complexity
If traditional coil assembly without metal connecting member is used, then structure is simpler, but automatic manufacturing and component replacement become difficult
Solution Approach 1:
By introducing the metal connecting member as a separate element, the patent creates distinct functional modules (coil assembly and conductive member) that can be independently manufactured and tested. This segmentation enables automatic manufacturing equipment to handle and assemble these modules through standardized interfaces, and also allows damaged components to be easily replaced by simply detaching and reattaching modules without complex soldering operations.
Solution Approach 2:
The metal connecting member acts as an intermediary that provides a standardized, easily detachable interface between the coil and conductive member. This intermediary design enables automatic manufacturing systems to perform quick connection operations and facilitates easy component replacement for maintenance or recycling, overcoming the limitations of traditional direct soldered connections while adding only minimal structural complexity.
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 solution enhances manufacturing efficiency by allowing for automatic assembly of electromagnetic drivers, reducing manual labor and facilitating the replacement and recycling of damaged components.
Implementation Method 1
The metal connecting member is electrically connected to a lead-out wire of the coil and a conductive member. At least a magnetic member is arranged corresponding to the coil assemble and separated with the coil assemble. The magnetic member has electromagnetic interaction with the coil when electric current flows through the coil.
Data Source
AI summary
An electromagnetic driver with lead-out structure for coil includes at least one coil holder and at least one coil disposed on the coil holder. The coil holder has a plurality of metal connecting member, and the two lead-out ends of the coil are electrically connected to the first connecting terminals of the metal connecting members. The second connecting terminal of the metal connecting member is electrically connected to a conductive member, such as spring, and the coil of the electromagnetic driver can be independently and automatically manufactured and then assembled with the other conductive member. The coil of the electromagnetic driver can be directly replaced at maintenance.