Flat-Wire Coil Terminal Recess Layout for Easy Lead Connection

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Solution Overview

Problem

Existing coil devices struggle to easily connect lead-out portions of flat wire coils to terminals, as crimping methods used for round wire coils are ineffective for flat wire coils.

Innovation Solution

A coil device design featuring terminals with accommodation recessed portions that allow for easy connection of flat wire coil lead-out portions without crimping, by displacing these recessed portions along the winding axis direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If crimping method is used to connect terminal to lead-out portion, then connection is possible for round wire coils, but connection becomes difficult for flat wire coils

Engineering Contradiction:

Improveease of connectionVSAvoidapplicability to flat wire

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The invention changes the connection method from crimping (mechanical deformation) to accommodation (geometric fitting). The terminal structure is modified to include accommodation recessed portions that geometrically match the flat wire lead-out portions, enabling easy connection without crimping operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of actively crimping the terminal onto the lead-out portion (terminal-initiated connection), the invention inverts the approach by having the lead-out portion passively fit into the accommodation recessed portion (lead-out portion-initiated connection). This reversal enables flat wire coils to be connected without requiring crimping force.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If accommodation recessed portions are displaced along winding axis direction, then lead-out portions can be connected without unnecessary bending, but terminal structure becomes more complex

Engineering Contradiction:

Improveease of connectionVSAvoidterminal structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The invention introduces displacement along the winding axis direction (Z-axis) as a new dimensional degree of freedom in the terminal structure. By positioning accommodation recessed portions at different Z-axis locations, the patent enables direct connection of lead-out portions without bending, transforming a 2D planar connection problem into a 3D spatial accommodation problem.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The terminal is segmented into multiple wire connecting portions (first and second wire connecting portions), each with its own accommodation recessed portion positioned at different locations along the winding axis. This segmentation allows each lead-out portion to be independently accommodated in its optimal position, simplifying the connection operation.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12205757B2Coil device

Publication Date: 2025.01.21 TDK CORP

AI summary

A highly reliable coil device is provided. An inductor 1 includes a coil 2 formed of a flat wire, a first terminal 4a including a first wire connecting portion 42a formed with a first accommodation recessed portion 421a in which a first lead-out portion 3a of the coil 2 is accommodated, and a second terminal 4b including a second wire connecting portion 42b formed with a second accommodation recessed portion 421b in which a second lead-out portion 3b of the coil 2 is accommodated, in which the first accommodation recessed portion 421a and the second accommodation recessed portion 421b are displaced from each other along a winding axis direction of the coil 2.