Inductor Lead Masking for Residue-Free Spray Painting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for painting inductors using adhesive tape result in residual glue on leads, causing structural damage, increased cleaning time, and soldering issues when connecting with external circuits.
Innovation Solution
The method involves using non-adhesive tapes or fixtures to cover leads during painting, and employing ultrasonic equipment or laser beams to precisely control paint application and removal, ensuring no paint is left on the leads, thus eliminating the need for glue removal and potential soldering issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive tape is used to cover leads during painting, then the painting process can be completed, but residual glue remains on leads causing structural damage and soldering issues
Solution Approach 1:
The patent extracts the adhesive property from the masking tape, using non-adhesive masking tape instead. This removes the harmful adhesive substance that causes residue and damage, while retaining the masking function of protecting leads from paint.
Solution Approach 2:
The patent introduces a fixture as an intermediary tool to hold and position the inductor body during painting. This fixture serves as a mediator that enables precise painting without direct contact between the painting equipment and the inductor, improving manufacturing ease while maintaining reliability.
2Ease of manufacture
If adhesive tape is used to cover leads during painting, then the painting process can be completed, but extra cleaning work is required to remove glue
Solution Approach 1:
By removing the adhesive component from the masking tape, the patent eliminates the need for glue removal cleaning steps. The non-adhesive tape can be easily removed without leaving residue, significantly reducing cleaning time and effort.
Solution Approach 2:
The patent employs disposable non-adhesive masking tape that can be easily discarded after use. This single-use approach eliminates the need for time-consuming cleaning processes, as the tape is simply removed and discarded without requiring any adhesive residue removal.
3Manufacturing precision
If paint is sprayed on all surfaces including leads, then complete coating is achieved, but paint stains on leads cause soldering issues
Solution Approach 1:
The patent segments the inductor components by using masking tape to separate the leads from the body during painting. This segmentation allows the body to receive complete paint coating while the leads remain protected, preventing paint contamination on the leads.
Solution Approach 2:
The masking tape acts as an intermediary barrier between the paint spray and the leads. It allows the painting process to proceed on all surfaces of the body while preventing paint from reaching and contaminating the leads, thus avoiding soldering issues.
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 approach saves time and cost by preventing structural damage and ensuring cleaner leads for connection with external circuits, reducing the risk of soldering issues and maintaining the integrity of the inductor components.
Implementation Method 1
removing the paint on the first area of the first surface of the first lead by a laser beam
Implementation Method 2
employing ultrasonic equipment or laser beams to precisely control paint application and removal
Data Source
AI summary
Multiple methods are provided to paint a body of an inductor so that there is no residual glue remained in the lead that may cause extra cleaning work and soldering issues when the lead is soldered with an external circuit.