Inductor U-Bend Lead Structure for Safer Spot Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing small-sized inductors is that the spot welding process often damages the insulation layer of the coil due to the welding head touching the coil body, leading to short circuits, which necessitates reducing the coil size and compromising electrical specifications.
Innovation Solution
The introduction of a U-bend portion in the coil lead, which allows for a longer lead and increased space between the coil body and the welding area, preventing the welding head from touching the coil during spot welding and facilitating the connection between the coil and the conductive lead frame, while also enabling the reduction of inductor size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the spot welding position is reduced close to the coil body to minimize inductor size, then the inductor size is reduced, but the welding head touches the coil body causing insulation damage and short circuits
Solution Approach 1:
The lead is bent into a U-shape configuration, transforming a linear arrangement into a three-dimensional structure. This dimensional change creates spatial separation between the welding position and the coil body, allowing the welding head to access the lead for connection without touching the coil body, thus preventing insulation damage while maintaining compact inductor size
Solution Approach 2:
The U-shaped lead configuration acts as an intermediary element between the coil body and the welding head. By routing the lead through a U-bend, it provides a safe distance and physical barrier that prevents the welding head from directly contacting the coil body during the spot welding process, thereby protecting the coil insulation while still enabling electrical connection
2Reliability
If the lead is made longer with a U-bend portion to prevent welding head contact, then the welding head can avoid touching the coil body, but the device complexity increases
Solution Approach 1:
The lead is segmented into distinct functional portions: a first portion extending from the coil body, a U-bend portion in the middle, and a second portion for welding connection. This segmentation allows each portion to serve its specific function - the first portion connects to the coil, the U-bend provides spatial separation and protection, and the second portion facilitates welding - thereby achieving reliable welding protection without excessive overall complexity
Data Source
AI summary
An inductor includes a coil, a conductive lead frame, and a housing. The coil includes a coil body and a lead protruding from the coil body. The lead has a U-bend portion. The lead is electrically fixed onto the conductive lead frame. The housing encapsulates the coil and exposes the conductive lead frame. A method of manufacturing an inductor includes the following steps: providing a coil, providing a conductive lead frame, making a lead of the coil be electrically fixed onto the conductive lead frame, bending the lead to form a U-bend portion and make the main body of the coil close to a portion of the lead that connects with the conductive lead frame, and forming a housing to encapsulate the coil and expose the conductive lead frame.