Coil Component Welded Ball Connection Reliability
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Solution Overview
Problem
The existing coil component technology experiences low connection reliability between the conducting wire and terminal electrode due to excessive welding, which leads to increased electrical resistance and mechanical stress, causing potential disconnection.
Innovation Solution
A coil component design where the conducting wire is integrated into a welded ball that is electrically and mechanically connected to both terminal pieces, covering the entire periphery of the wire, thereby enhancing resistance to physical forces and chemical erosion, and ensuring reliable electrical conductivity even if disconnection occurs at one terminal piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is applied to connect the conducting wire to the terminal electrode, then electrical conductivity is improved, but excessive welding causes molten metal to protrude and reach the bent portion or base portion, causing partial melting or deformation
Solution Approach 1:
The insulating coating layer acts as an intermediary protective barrier between the conducting wire and the terminal electrode during welding. It prevents excessive welding by blocking the laser beam and molten metal from reaching the bent portion and base portion, while still allowing controlled welding at the connection point where the coating is removed.
Solution Approach 2:
The insulating coating layer is selectively removed only at the specific location where welding is needed (the connection point between conducting wire and terminal electrode), while the coating remains intact at other locations (bent portion and base portion) to provide protection. This local modification enables precise control of the welding process.
2Reliability
If the insulating coating layer is removed to enable welding, then electrical connection is improved, but the conducting wire becomes vulnerable to physical external forces
Solution Approach 1:
The insulating coating layer is removed only at the specific welding location to enable electrical connection, while the coating remains intact at other portions of the conducting wire to provide mechanical protection against physical external forces. This localized approach balances electrical connectivity needs with mechanical strength requirements.
3Reliability
If the welded ball protrudes from the receiving portion, then electrical conductivity is ensured, but the bent portion or base portion may be affected by physical external forces
Solution Approach 1:
The insulating coating layer serves as a mediator that limits the protrusion of the welded ball by providing a physical barrier. This prevents the welded ball from extending too far and exposing the bent portion or base portion to mechanical stress, while still ensuring adequate electrical conductivity at the connection point.
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
The solution significantly increases the reliability of both electrical and mechanical connections by distributing the welded ball across the entire periphery of the conducting wire, reducing electrical resistance and ensuring continued conductivity despite mechanical stress.
Implementation Method 1
a portion of the insulating coating layer 5 of the conducting wire 3 on a distal end side with respect to the holding portion 13 is removed. To remove the insulating coating layer 5, for example, irradiation with laser light is applied.
Implementation Method 2
the welding portion 11 is irradiated with laser light. Hence, the center conductor 4 of the conducting wire 3 and the welding portion 11 are molten and mixed
Implementation Method 3
a liquefied molten portion becomes a substantially ball-like shape by surface tension. Consequently, the welded ball 14 is formed
Data Source
AI summary
A coil component includes a conducting wire and a terminal electrode. The terminal electrode includes a first terminal piece and a second terminal piece that face and overlap each other with the conducting wire interposed therebetween. The first terminal piece and the second terminal piece are coupled to one another with a coupling portion and are integrated in a welded ball at a position different from a position of the coupling portion. An end portion of the conducting wire is in the welded ball.