Coil Device Wire Connection Structure Asymmetry

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Solution Overview

Problem

The existing wire connection structure in coil devices, such as those in engine start switches, requires frequent changes in nozzle insertion direction during wire winding, leading to increased noise, complex jig movements, and higher man-hours for automatic wire winding machines.

Innovation Solution

A wire connection structure where the entwining and fusing portions of the terminals are disposed orthogonal to the axial direction of the bobbin, allowing for consistent nozzle insertion direction and simplifying the wire winding process by integrating these portions on a plate-like body with resin molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entwining portions of terminals are disposed in diametrically-opposed manner, then wire connection reliability is improved, but nozzle insertion direction must be changed 180 degrees between terminals, increasing device complexity and reducing productivity

Engineering Contradiction:

Improvewire connection reliabilityVSAvoidjig mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies asymmetry by positioning both entwining portions (first and second entwining portions) on the same side of the terminal rather than in diametrically-opposed positions. This asymmetric arrangement allows the nozzle to entwine wires at both positions without changing insertion direction, resolving the contradiction between maintaining connection reliability and reducing jig mechanism complexity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent changes the spatial dimension of the entwining portions from a radial/diametric arrangement to a longitudinal arrangement along the terminal length. This dimensional reconfiguration allows sequential access to both entwining portions from the same nozzle direction, eliminating the need for 180-degree direction changes while maintaining reliable wire connection

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If the nozzle insertion direction is changed between terminals, then wire entwinning at diametrically-opposed positions is achieved, but manufacturing time increases and productivity decreases

Engineering Contradiction:

Improvewire entwinning precisionVSAvoidwire winding productivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent enables continuous useful action by allowing the nozzle to entwine wires at both first and second entwining portions without changing insertion direction. This continuous operation from a fixed nozzle position eliminates idle time for direction changes, thereby improving productivity while maintaining precise wire entwinning through the properly positioned entwining portions

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If frequent changes in nozzle insertion direction are required, then wire connection at opposite terminal positions is achieved, but noise increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvewire connection stabilityVSAvoidmanufacturing noise

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-positioning both entwining portions on the same side of the terminal before the wire winding process begins. This preliminary configuration allows the nozzle to perform both entwining operations from a single insertion direction, eliminating the need for direction changes that generate noise, while still achieving reliable wire connection at both positions

Inventive Principle:

Principle #10Preliminary action

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 reduces noise and manufacturing steps, simplifies the jig mechanism, and decreases man-hours required for wire winding by enabling automatic entwining and thermal caulking without changing nozzle orientation.

Implementation Method 1

the winding start portion 12a passed through the fusing portion 13c is fixed to the first terminal 13 by applying thermal caulking to the fusing portion 13c

Methodology Applied

Scientific EffectThermal caulking: Welding

Data Source

PatentUS10026545B2Wire connection structure of coil device

Publication Date: 2018.07.17 U SHIN LTD

AI summary

A structure includes first and second terminals to fix a winding start portion and a winding end portion of a coil antenna formed by winding wire around a bobbin. The first terminal includes a fusing portion that connects the winding start portion to first and second entwining portions of the winding start portion. The second terminal includes a fusing portion that connects the winding end portion to first and second entwining portions of the winding end portion. Further, the entwining portions and the fusing portions of the first and second terminals are disposed orthogonal to an axial direction of a cylindrical portion of the bobbin and further are formed in the same direction.