Coil Component Terminal Wire Bonding via Thermocompression
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Solution Overview
Problem
The existing method of connecting a wire to a metal terminal in coil component manufacturing is complex, requiring separate bending operations for the holding and welding portions, leading to increased manufacturing complexity and the need for specialized devices.
Innovation Solution
A method involving thermocompression bonding, where heat and pressure are applied to temporarily fix the wire using the molten or softened insulating resin coating as an adhesive, simplifying the process by eliminating the need for a separate holding portion and allowing for a single bending operation to establish contact for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate holding portion is provided to temporarily fix the wire before welding, then the wire can be securely positioned, but the metal terminal structure becomes more complex and requires additional bending operations
Solution Approach 1:
The patent merges the holding function and welding function into a single integrated connecting portion. The connecting portion is bent by way of a single bending scheduled portion to simultaneously achieve wire holding and welding contact, eliminating the need for separate holding and welding portions. This reduces structural complexity while maintaining the temporary fixing capability during the welding process.
2Manufacturing precision
If separate bending operations are performed for holding and welding portions, then each portion can be precisely positioned, but the manufacturing process becomes more complex and requires specialized devices
Solution Approach 1:
The patent combines multiple bending operations into a single bending operation. The connecting portion is bent by way of a single bending scheduled portion, which simultaneously positions both the holding segment and welding segment. This eliminates the need for separate bending operations and specialized devices, simplifying the manufacturing process while maintaining positioning precision through proper design of the bending scheduled portion.
Solution Approach 2:
The patent incorporates a bending scheduled portion that is pre-designed to achieve the correct positioning of both holding and welding portions in a single bending operation. This preliminary design of the bending schedule ensures that the connecting portion attains the proper configuration before welding, eliminating the need for subsequent adjustment operations.
3Reliability
If the insulating resin coating is removed to expose the conductive wire for welding, then welding can be performed, but the wire structure becomes more complex and additional processing steps are required
Solution Approach 1:
The patent extracts or removes a portion of the insulating resin coating from the wire to expose the conductive wire portion. This exposed portion enables direct contact with the welding portion of the metal terminal, allowing welding to be performed without requiring complex wire structure modifications. The insulating coating is selectively removed only at the necessary location to facilitate welding while maintaining insulation elsewhere.
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 approach simplifies the manufacturing process, reduces device requirements, and ensures a favorable welding state by exposing the conductive wire portion from the insulating resin coating, resulting in a reliable connection between the wire and metal terminal.
Implementation Method 1
a thermocompression bonding step of applying heat and pressure in a state where the wire is placed on the receiving portion thus adhering the wire to the receiving portion using the molten or softened insulating resin coating as an adhesive agent
Implementation Method 2
using the molten or softened insulating resin coating as an adhesive agent
Data Source
AI summary
A metal terminal where a connecting portion has a receiving portion which receives a wire and a contact segment which extends from the receiving portion by way of a bending scheduled portion is prepared. By applying heat and pressure in a state where the wire is placed on the receiving portion for temporarily fixing the wire, the wire is adhered to the receiving portion using a molten or softened insulating resin coating as an adhesive agent. Next, the connecting portion is bent by way of the bending scheduled portion such that the contact segment faces the receiving portion by way of the wire and the contact segment is brought into contact with the wire. Next, by irradiating a laser beam to a portion of the metal terminal, the wire and the metal terminal are welded to each other.