Magnetic Component Terminal Fixing Structure

Solution Overview

Problem

Existing magnetic components face reliability and stability issues due to the lack of secure connection between lead wires and terminals, often resulting in disconnection during surface-mounting processes when binding is omitted.

Innovation Solution

A magnetic component design featuring terminal end fixing portions that receive and position lead wire ends, ensuring stable connection through soldering or welding, with protruding portions and angled projections to enhance contact area and prevent slippage, allowing for secure attachment without binding the lead wire ends to terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the binding process is omitted and only surface welding or soldering is used to connect lead wire ends to terminals, then the manufacturing process is simplified, but the connection reliability and stability deteriorate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The terminal end fixing portions are formed on the terminals in advance before the lead wire connection process. These fixing portions pre-establish a mechanical retention structure that will later secure the lead wire ends, eliminating the need for separate binding operations while ensuring connection reliability from the outset

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The terminal end fixing portions act as an intermediary element between the terminals and the lead wire ends. They provide a mechanical interlocking interface that supplements the electrical connection, preventing disconnection during surface-mounting while maintaining process simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the binding process is omitted and only surface welding or soldering is used to connect lead wire ends to terminals, then the manufacturing process is simplified, but the connection stability deteriorates leading to disconnection during surface-mounting

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The terminal end fixing portions are formed on the terminals in advance before the lead wire connection process. These fixing portions pre-establish a mechanical retention structure that will later secure the lead wire ends, eliminating the need for separate binding operations while ensuring connection reliability from the outset

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The terminal end fixing portions act as an intermediary element between the terminals and the lead wire ends. They provide a mechanical interlocking interface that supplements the electrical connection, preventing disconnection during surface-mounting while maintaining process simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2197004B8Magnetic component

Publication Date: 2016.08.17 SUMIDA CORP

AI summary

Provided is a magnetic component capable of omitting a process of binding both ends of a lead wire to terminals and having stable connection between the lead wire and the terminals. The magnetic component is provided with a core (2) including a spool portion around which a lead wire (3) is wound, and external terminals (4, 5) to which the both ends of the lead wire (3) are connected. Each of the external terminals (4, 5) includes a protruding portion (terminal end fixing portion) which is capable of receiving movement of the lead wire (3) in a direction opposite to a winding direction; and the external terminals (4, 5) and the lead wire (3) are connected to each other.