Coil Component Welding with Insulation Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing connection structure between a wire and a terminal electrode in coil components, as described in Japanese Patent No. 4184394, results in low reliability and mechanical strength due to the insulating coating layer interfering with the welding process, leading to increased electric resistance and potential blowholes.
Innovation Solution
A coil component design where the central conductor of the wire is welded to both the receiving portion and the weld nugget portion of the terminal electrode, with the insulating coating layer removed from the entire circumference, ensuring a strong mechanical and electrical connection without interference from coating substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the insulating coating layer is left on the wire during welding, then heat transfer to the core is reduced, but the welding reliability and mechanical strength deteriorate due to coating interference
Solution Approach 1:
The insulating coating layer is removed in advance from the portion of the wire that will be welded to the terminal electrode. This preliminary removal action ensures that the welding process can proceed without interference from the coating, achieving reliable mechanical and electrical connection, while the insulating coating remains intact on other portions to provide necessary insulation and protect against heat transfer to the core.
2Reliability
If the insulating coating layer is removed from the wire, then welding reliability and mechanical strength improve, but the risk of heat affecting the core increases
Solution Approach 1:
The insulating coating layer is selectively removed only from the specific local area where welding is required, while leaving the coating intact on other portions of the wire. This localized removal approach allows the welding process to achieve high reliability and mechanical strength at the connection point, while the remaining coating provides continued protection against heat transfer to the core in other areas.
3Strength
If the wire is welded to both the receiving portion and the weld nugget portion, then mechanical strength and electrical conductivity improve, but the manufacturing complexity increases
Solution Approach 1:
The wire is welded to both the receiving portion and the weld nugget portion of the terminal electrode, merging multiple connection points into a unified welding structure. This combining approach creates a more robust mechanical and electrical connection by distributing the connection across multiple contact areas, thereby improving overall strength and conductivity while the integrated design maintains manufacturing feasibility.
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 mechanical strength, reduces electric resistance, and increases reliability by preventing the formation of blowholes, while minimizing heat transfer to the core during welding.
Implementation Method 1
laser beam welding is used. The weld piece 81 is irradiated with a laser beam, and the central conductor 74 of the wire 73 and the weld piece 81 are thereby melted
Implementation Method 2
the central conductor 74 of the wire 73 and the weld piece 81 are welded to each other
Implementation Method 3
a molten metal is formed into a ball shape due to surface tension during welding and is cooled and solidified
Implementation Method 4
a molten metal is formed into a ball shape due to surface tension during welding and is cooled and solidified
Implementation Method 5
The insulating coating layer 75 is removed by using, for example, laser beam radiation
Data Source
AI summary
A coil component includes a wire including a linear central conductor and an insulating coating layer that covers a circumferential surface of the central conductor, and a terminal electrode that is electrically connected to the central conductor at an end portion of the wire. The terminal electrode includes a receiving portion to which the central conductor is welded. A weld nugget portion that is produced when the central conductor is welded and the receiving portion are welded to each other.