Coil Terminal Slit Design for Stable Coated Wire Soldering
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Solution Overview
Problem
Existing coil terminal connections with coated wires suffer from unstable connections due to the lack of a holding unit, leading to poor bonding strength and quality, especially when soldering, as the coated wire is bent to fit, causing stress on the core wire.
Innovation Solution
A coil terminal design featuring a terminal body with parallel beam portions forming a slit, allowing the coated wire to fit within and be soldered to a base portion without bending, thereby preventing stress on the core wire and ensuring a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coated wire is soldered to the coil terminal by bending the wire to fit the bonding surface, then the wire can be connected to the terminal, but stress is applied to the core wire resulting in degraded bonding strength
Solution Approach 1:
The coil terminal is pre-formed with a protrusion that extends toward the coated wire before soldering occurs. This preliminary structural preparation allows the coated wire to be positioned correctly without bending, eliminating stress on the core wire while maintaining ease of assembly and soldering
Solution Approach 2:
The protrusion on the coil terminal acts as an intermediary element between the coated wire and the bonding surface. It provides a support structure that bridges the gap created by the insulation coating thickness, allowing the core wire to be soldered directly to the bonding surface without bending
2Device complexity
If no holding unit is provided for the coated wire on the coil terminal, then the structure remains simple, but the connection becomes unstable leading to poor quality
Solution Approach 1:
The protrusion on the coil terminal serves multiple functions: it acts as a positioning element to hold the coated wire in place, provides mechanical support to prevent instability, and facilitates proper alignment for soldering. This single structural feature combines multiple functions without adding complex separate components
Solution Approach 2:
The protrusion extends in a direction toward the coated wire from the bonding surface, creating a three-dimensional structural feature that provides holding capability. This dimensional addition to the otherwise flat terminal structure enables stable connection without complicating the overall design
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 bonding strength and stability of the connection between the coated wire and the coil terminal by eliminating the need for bending the wire, resulting in a more reliable electrical connection.
Implementation Method 1
a core wire at the tip end of the coated wire is capable of being soldered to the base portion
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
According to one embodiment, a coil terminal (28A, 28B) is electrically connected to a coil (22) being wound around an electromagnetic block (2) and connected to a coated wire (8). The coil terminal (28A, 28B) includes a connection portion (281) electrically connected to the coil (22) and a terminal body portion (282) extending from the connection portion (281) and connected to the coated wire (8). The terminal body portion (282) includes a base portion (282b) formed on a first end of the coil terminal (28A, 28B), and a pair of parallel beam portions (282c, 282e) extending toward a second end of the coil terminal (28A, 28B) from the base portion (282b). The parallel beam portions (282c, 282e) protrude in a thickness direction of the terminal body portion (282) and form a slit (282a) interposed between the pair of parallel beam portions (282c, 282e). The coated wire (8) fits within the slit (282a) and a core wire (81) at the tip end of the coated wire (8) is soldered to the base portion (282b).