Figure-of-Eight Laminated Coil Production Method
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Solution Overview
Problem
Current methods for producing laminated coils require multiple processes, including soldering and length measurement, leading to increased costs, reduced productivity, and potential stress concentration and reliability issues due to complex connection methods.
Innovation Solution
A method that consecutively produces coil parts from a single flat coil by bending it into an angular tube shape, forming a connection portion, and spreading it to align both parts on the same plane, eliminating the need for additional connection processes and length measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first coil part and the second coil part are separately produced and connected by soldering, then the inductance performance can be achieved, but the number of production processes increases and mass productivity deteriorates
Solution Approach 1:
The patent merges the first coil part and second coil part into a single continuously formed component. The flat coil is bent to form both coil parts in sequence without separation, eliminating the need for soldering connections and insulation processing between separate parts, thereby improving mass productivity while maintaining inductance performance.
Solution Approach 2:
The connection portion is formed in advance during the continuous bending process of the flat coil, before any connection operations would be needed. The bending creates the connection structure between coil parts as an integrated part of the manufacturing process, eliminating subsequent connection steps.
2Reliability
If separate coil parts are connected by soldering, then electrical connection can be achieved, but costs increase due to additional processes
Solution Approach 1:
The patent combines the formation of both coil parts and their connection into a single continuous bending operation. This eliminates soldering, insulation processing, and electrical characteristic inspection processes, thereby reducing production costs while ensuring reliable electrical connection through the integrated structure.
Solution Approach 2:
The patent extracts and eliminates the soldering connection process and associated insulation and inspection processes from the manufacturing flow. The connection is achieved purely through the bending geometry of the flat coil, removing unnecessary costly steps.
3Productivity
If the second coil part is bent at 180° to form a bent connection portion, then consecutive production is achieved, but stress concentration occurs in the bent connection portion
Solution Approach 1:
The patent uses asymmetric bending angles for the connection portion, specifically setting the first bending angle to 90° and the second bending angle to 45°. This asymmetric configuration distributes stress more evenly compared to a 180° bend, maintaining reliability while enabling consecutive production.
Solution Approach 2:
The patent changes the bending angle parameters from the conventional 180° to specific values (90° and 45°). This parameter modification reduces stress concentration in the connection portion while maintaining the ability to produce coils consecutively in a continuous process.
4Manufacturing precision
If length measurement and division processes are added to form stacked angular tube shape coils, then connection precision can be improved, but the number of processes increases and efficiency decreases
Solution Approach 1:
The flat coil itself serves as the measuring and positioning reference during the bending process. The initiation point is spaced from the first end by a predetermined distance, and the bending automatically creates the correct connection portion length and coil spacing without requiring external measurement and division operations, thereby maintaining precision while improving efficiency.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
There is provided a production method for a laminated coil, the production method including: a process of producing a coil part of one axis by stacking a flat coil in an axial direction, a process of bending the flat coil of a connection portion in an extended state thereof in a length direction to allow for the division of a first coil part and a second coil part, wherein the connection portion connecting two coil parts is produced by bending the flat coil of the connection portion, and a process of finally spreading the bent connection portion, such that the first coil part and the second coil part may be disposed to be parallel in the same direction on the same plane.