Coil Component Terminal Bending Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components face challenges in achieving high accuracy and uniformity in bending lead-out wires and terminals due to instability in thrusting force and variations in size, leading to increased costs and complexity in manufacturing.
Innovation Solution
A coil component design featuring a magnetic core with a tabular terminal and a groove for the lead-out wire, where the terminal is bent along the core's side surface, allowing surface contact with a jig for stable bending and reducing strain, ensuring accurate positioning and size consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lead-out wire is arranged on the upper surface side of the terminal before bending, then the terminal and lead-out wire can be bent simultaneously, but the thrusting force becomes unstable and bending accuracy decreases
Solution Approach 1:
The patent repositions the lead-out wire from the upper surface side to the lower surface side of the terminal, changing its spatial arrangement. This dimensional repositioning allows the wire to be arranged in a groove on the lower surface, enabling stable surface contact with the bending jig while maintaining simultaneous bending capability.
Solution Approach 2:
The patent introduces a groove structure as an intermediary element between the lead-out wire and the bending jig. This groove provides a defined seating position for the wire, ensuring stable contact and consistent thrusting force during the bending operation, thereby improving both accuracy and repeatability.
2Reliability
If crushing work is performed on the lead-out wire to improve contact, then contact quality improves, but the wire may get out of the groove causing size variation
Solution Approach 1:
The patent performs crushing work on the lead-out wire before placing it in the groove, preparing the wire surface in advance to improve contact quality. The wire is then securely positioned in the groove, and the subsequent bending operation maintains consistent positioning without causing the wire to protrude or vary in size.
3Manufacturing precision
If a groove is provided in the terminal for the lead-out wire, then positioning is improved, but the wire may still get out during bending causing size variation
Solution Approach 1:
The patent applies local quality by providing a groove with specific dimensional characteristics on the lower surface of the terminal. The groove has controlled width and depth that match the lead-out wire dimensions, creating a secure fit that prevents the wire from getting out during bending while maintaining precise positioning.
Data Source
AI summary
A coil component includes a core formed by a magnetic material, a coil embedded in the core, a part of a terminal portion of the coil protruded from a side surface of the core, and a tabular terminal, a part thereof protruded from the side surface of the core and partly connected with the protruded part of the terminal portion of the coil. The protruded part of the terminal portion of the coil and the protruded part of the tabular terminal are respectively bent toward the bottom surface side of the core along the side surface of the core, and the protruded and bent part of the terminal portion of the coil is arranged between the protruded and bent part of the tabular terminal and the core.