Hot-Air Coil Winding for Uniform Bonding Coat Polymerization
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Solution Overview
Problem
Conventional coil winding processes for RFID coils with copper wire bonding coats face inefficiencies in heating, leading to prolonged heating times and non-uniform polymerization, particularly affecting the external layers of the coil.
Innovation Solution
A coil winding device that incorporates a tool holder with uniformly distributed hot air outlet ports to inject hot air directly into the winding gap, ensuring consistent heating across all coil layers during the winding process, reducing heating time and improving polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating is carried out after coil winding, then the bonding coat can be polymerized, but the heating time becomes very long and machine cycle time increases
Solution Approach 1:
The patent applies preliminary action by integrating hot air injection directly into the coil winding process. The winding device includes a hot air injection device that heats the bonding coat during winding, rather than heating after winding is complete. This preliminary heating action during the winding process reduces the subsequent heating time required and accelerates the overall machine cycle while ensuring proper polymerization of the bonding coat.
2Reliability
If heating is carried out after coil winding, then polymerization can occur, but the heating is not optimal and not uniform, particularly on external layers
Solution Approach 1:
The patent applies local quality by positioning hot air injection nozzles at specific locations within the winding device to target different regions of the coil. The injection device includes multiple nozzles arranged to direct hot air at various layers of the coil during winding, ensuring that external layers receive adequate heating similar to internal layers. This localized heating approach achieves uniform polymerization across all coil layers rather than the non-uniform heating that occurs with post-winding oven heating.
3Reliability
If heating is carried out after coil winding, then the bonding coat can be polymerized, but the machine cycle time is increased
Solution Approach 1:
The patent applies merging by combining the heating function with the coil winding process. The winding device integrates a hot air injection device that operates simultaneously with the winding mechanism. The hot air injection device and winding mechanism work together in an integrated manner, allowing heating and winding to occur concurrently rather than sequentially. This merging of functions eliminates the separate post-winding heating step, reduces machine cycle time, and increases productivity while maintaining polymerization quality.
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 method enhances the polymerization quality of the bonding coat by uniformly heating all coil layers during the winding process, reducing machine cycle time and preventing coil disassembly, while maintaining optimal heating temperatures.
Implementation Method 1
The heating may be created by the injection of hot air
Implementation Method 2
A good polymerization of the bonding coat ensures that the layers of the coil stick together
Data Source
Figure 1~2
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AI summary
The present disclosure refers to a device and method for manufacturing a coil (16) having a defined number of windings (17). The method may comprise winding a wire (18) having a bonding coat in a winding gap (8) of a coil winding device (15), the winding gap (8) having a longitudinal dimension limiting a winding width (b) and a radial dimension limiting a winding height (h), injecting of hot air into the winding gap (8) during the winding step at least at a part of the radial dimension of the winding gap (8), and terminating the winding process when the coil (16) reaches a defined number of windings (17).