Coil Terminal Fitting Structure for Vibration-Resistant Flange Fixation
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Solution Overview
Problem
Existing winding-type coil devices face reliability issues due to terminal fittings being inadequately fixed to flanges, leading to detachment during board vibration or deformation.
Innovation Solution
The coil device incorporates a terminal fitting with an engagement part that clamps the circumferential wall of the flange, using a pair of clamping pieces to securely attach and a protrusion plate part to reduce DC resistance and prevent stress-induced detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminal fittings are fixed to flanges only via adhesive, then the mounting process is simple, but the fixation reliability deteriorates when the board vibrates or deforms
Solution Approach 1:
The terminal fitting is divided into multiple functional parts: a body portion, an engagement portion with clamping pieces, and a protrusion plate portion. This segmentation allows each part to perform its specific function - the engagement portion provides mechanical interlocking while the body portion maintains electrical connection, resolving the contradiction between simple mounting and reliable fixation.
Solution Approach 2:
The clamping pieces are designed to elastically deform during the engagement process, dynamically adapting to the flange's circumferential wall. This dynamic engagement allows the terminal fitting to firmly attach to the flange while accommodating minor variations in flange dimensions or deformation, thereby improving fixation reliability without complicating the mounting process.
2Volume of moving object
If the coil device is made compact, then the low profile is achieved, but the terminal fitting may detach under vibration or deformation
Solution Approach 1:
The engagement portion with clamping pieces is nested within the body portion of the terminal fitting, allowing the clamping mechanism to be integrated into the overall structure without significantly increasing the device's external dimensions. This nested design maintains a compact profile while providing reliable mechanical attachment through the engagement portion.
Solution Approach 2:
The terminal fitting employs a composite structure combining different functional elements - the body portion for electrical connection and the engagement portion with clamping pieces for mechanical attachment. This composite design allows the terminal fitting to achieve both compact dimensions and high attachment reliability by optimizing each component's function within the constrained space.
3Ease of manufacture
If the lead end connection structure is simplified, then the manufacturing is easier, but the DC resistance from lead end to external circuit increases
Solution Approach 1:
The body portion of the terminal fitting integrates both the electrical connection function and the mechanical attachment function into a single component. The lead end is directly connected to the body portion, which then connects to the external circuit through the main mounting surface. This merged structure eliminates intermediate connection elements, simplifying manufacturing while minimizing the number of electrical interfaces and reducing overall DC resistance.
Data Source
AI summary
A coil device includes a winding core, a flange, and a terminal fitting. The winding core is wound by a wire. The flange is formed at an end of the winding core in its axial direction. The terminal fitting is attached to the flange. The terminal fitting includes an engagement part engaged with a circumferential wall part of the flange.