Coil Device Terminal Electrode Resilient Lead Support
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Solution Overview
Problem
Conventional coil devices require special tools for temporary fixing of lead parts and terminal electrodes, which complicates the positioning and reliability of connections, especially when the lead part's projection position varies.
Innovation Solution
A coil device design featuring a core part with a magnetic material and resin, where the terminal electrode has a lead supporting part bent at a specific angle to form a bonding part with the lead part, allowing resilient deformation for secure contact and temporary fixation without the need for special tools, enabling stable connections through methods like laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure is applied to the lead part and terminal electrode to temporarily fix using a special device, then the lead part and terminal electrode can be fixed temporarily, but the device complexity increases and requires special tools
Solution Approach 1:
The terminal electrode's lead supporting part is designed to automatically perform the temporary fixing function through its own resilient deformation, eliminating the need for external special fixing devices. The bent lead supporting part naturally contacts and presses the lead part when the terminal electrode is installed, achieving self-service temporary fixation.
Solution Approach 2:
The lead supporting part acts as an intermediary element between the terminal electrode and the lead part. It provides a bridging function by deforming resiliently to accommodate position variations and establish reliable contact, serving as a mediator that enables connection without requiring complex external fixing devices.
2Manufacturing precision
If the lead part position varies, then the bonding position may be inaccurate, but using special fixing devices increases device complexity
Solution Approach 1:
The lead supporting part is designed with resilient properties that allow it to change its physical state (deform) in response to position variations of the lead part. This parameter change capability enables the lead supporting part to adapt to different lead part positions and maintain accurate bonding alignment without requiring complex positioning devices.
Solution Approach 2:
The lead supporting part transitions from a static rigid structure to a dynamic resilient structure that can deform and adapt. This dynamic characteristic allows the lead supporting part to automatically adjust to position variations of the lead part, maintaining bonding precision without needing complex external fixing mechanisms.
3Reliability
If a special device is used for temporary fixing, then the connection can be stabilized, but the ease of operation decreases
Solution Approach 1:
The terminal electrode structure performs its own positioning and temporary fixing function through the resilient deformation of the lead supporting part, eliminating the need for external special devices. This self-service mechanism simplifies the operation process while maintaining connection stability.
4Adaptability or versatility
If the lead supporting part has a crossing angle less than 90 degrees, then the resilient deformation capability is improved, but the structural complexity increases
Solution Approach 1:
The lead supporting part is designed with a bent configuration featuring a specific crossing angle less than 90 degrees. This curved geometry enables the lead supporting part to deform resiliently and adapt to position variations, providing adaptability while the bending itself is a simple geometric feature rather than a complex mechanism.
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 ease of positioning and reliability of connections between the lead and terminal electrodes, allowing for stable bonding without requiring special tools for temporary fixing, even when the lead part's position varies, and improves the quality of the bonding process.
Implementation Method 1
the lead supporting part (or the lead part or both/the same applies hereinafter) resiliently deforms; thereby the tip part of the lead supporting part securely contacts with the lead part. Furthermore, because the lead supporting part is resiliently deformed, the lead part is temporarily fixed while positioned on the lead supporting part by being pressed with the resilient force.
Data Source
AI summary
At the position where the lead art of the wire is projecting out from the outer face of the core part and spaced apart from the side face, the bonding part between the lead part and the terminal electrode is formed. The terminal electrode comprises the terminal body installed along the side face of the core body, and the lead supporting part bended from the terminal body towards the bonding part at the near position where the lead part projects out from the side face of the core part. The crossing angle of the lead supporting part with respect to the side face of the core body is less than 90 degrees.