Transformer Output Wire Joining Structure for Uniform Soldering
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Solution Overview
Problem
The existing methods for joining output wires to metal pins in transformer or inductor winding structures are prone to uneven soldering, incomplete connections, and high impedance, requiring skilled manual winding and resulting in defects that affect appearance and performance.
Innovation Solution
An output wire joining structure featuring a winding seat with pin holders, positioning protrusions, and joining plates allows for easy and uniform soldering of output wires to metal pins, eliminating the need for complex winding and ensuring secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual winding of metal wires around metal pins is used to connect output wires, then the connection can be formed, but the soldering becomes uneven and quality control becomes difficult
Solution Approach 1:
The connection structure is segmented into distinct functional components: pin holders for positioning metal pins, joining plates for providing soldering surfaces, and positioning protrusions for aligning output wires. This segmentation allows each component to perform its specific function optimally, ensuring uniform soldering while simplifying the overall process.
Solution Approach 2:
Joining plates serve as intermediary elements between the output wires and metal pins. These plates provide a standardized soldering surface that mediates the connection process, eliminating the need for complex manual winding and ensuring consistent soldering quality across all connections.
2Productivity
If manual winding skills are required for connecting wires, then connections can be made, but labor costs increase and production efficiency decreases
Solution Approach 1:
The pin holders and joining plates are designed to self-align and self-position components during assembly. The positioning protrusions automatically guide output wires into correct positions, and the joining plates naturally align with metal pins, eliminating the need for skilled manual winding operations and enabling straightforward assembly.
Solution Approach 2:
The invention changes the fundamental parameter of the connection process from manual dexterity-based winding to standardized component assembly. By transforming the process into one that relies on pre-defined geometric parameters (positioning protrusions, accommodating grooves, joining plate dimensions), the skill requirement is dramatically reduced while productivity increases.
3Reliability
If complex winding processes are used to connect output wires, then connections can be formed, but the appearance becomes less aesthetic and defects increase
Solution Approach 1:
The pin holders and joining plates are pre-configured with positioning protrusions and accommodating grooves that pre-establish the correct geometric relationships between all components. This preliminary arrangement ensures that when assembly occurs, components naturally align into aesthetically pleasing and reliable configurations without complex winding operations.
Solution Approach 2:
The invention merges the positioning, supporting, and soldering functions into an integrated assembly of pin holders and joining plates. This consolidation eliminates the need for separate winding operations, resulting in both improved appearance (no loose wires or complex windings visible) and enhanced reliability (consistent, controlled connections).
Data Source
AI summary
An output wire joining structure of a winding seat for a transformer or an inductor is disclosed. The winding seat includes a winding portion and a support portion. The winding portion is disposed on top of the support portion for winding a coil. Two sides of the support portion are provided with pin holders for insertion of output wires of the coil. At least one joining plate is disposed beneath the pin holders corresponding in position to the output wires. The output wires of the coil and metal pins of the pin holders are soldered to the joining plate respectively, so that the output wires and the metal pins are quickly soldered and fixed to form a connection, which has the advantages of increasing the rated current and facilitating the operation.