Coil Terminal Coating Structure for Stable Soldering Connection
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Solution Overview
Problem
Conventional coil structures in wireless transmitters face issues with the terminal part of the metal wire not being easily positioned for soldering, leading to loose winding turns and instability during the soldering process.
Innovation Solution
A coating layer is applied to encapsulate the terminal part of the metal wire and the winding turns of the coil to maintain stability and facilitate secure electrical connections during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal part of the metal wire is exposed from the insulating layer for electrical connection, then electrical connectivity is achieved, but the terminal part cannot be positioned firmly during soldering
Solution Approach 1:
The insulating layer is segmented to expose only the terminal part of the metal wire while the rest remains encapsulated. This segmentation allows the terminal part to be positioned on the soldering board for electrical connection while maintaining insulation on the coil body, resolving the contradiction between electrical connectivity and positioning stability.
Solution Approach 2:
The insulating layer provides different properties at different locations: it is removed or exposed at the terminal part to enable positioning and soldering, while remaining intact on the coil windings to provide insulation. This local differentiation resolves the contradiction by allowing the terminal part to be positioned firmly during soldering while maintaining electrical isolation where needed.
2Ease of manufacture
If conventional coil structure is used without coating layer, then manufacturing simplicity is maintained, but winding turns become loose during soldering process
Solution Approach 1:
A coating layer is applied in advance to the insulating layer before the soldering process. This preliminary coating action prevents the winding turns from becoming loose during subsequent soldering operations, resolving the contradiction between manufacturing simplicity and structural stability by adding a preventive measure that maintains coil integrity throughout the manufacturing process.
3Reliability
If the terminal part is exposed for soldering connection, then electrical connectivity is achieved, but the relative positions of winding turns change during soldering
Solution Approach 1:
The coil structure is segmented into the coil windings and the terminal part. The insulating layer is selectively removed or exposed only at the terminal part, allowing it to be positioned and soldered without affecting the position of the winding turns. This segmentation resolves the contradiction by isolating the positioning function to the terminal part while maintaining winding turn position precision.
Solution Approach 2:
The insulating layer provides localized insulation on the coil windings while being exposed at the terminal part. This local quality differentiation allows the terminal part to be positioned precisely for soldering without causing the winding turns to shift, maintaining manufacturing precision while achieving electrical connectivity.
Data Source
AI summary
A coil structure comprises a coil and a conductive terminal part, wherein the coil is formed by a conductive wire comprising a metal wire and at least one insulating layer encapsulating the metal wire, wherein a first terminal part of the metal wire is exposed from the at least one insulating layer, wherein a first portion of the conductive terminal part encapsulates the first terminal part of the metal wire and a second portion of the conductive terminal part extends from said first portion as an electrode for electrically connecting to an external circuit.