Voice Coil Foil-Terminal Structure for Rust-Free End Connection
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Solution Overview
Problem
The conventional method of removing insulation films from electric wires in voice coils requires precise and time-consuming processes, leading to increased production costs and reduced coil lifetime due to rust exposure at non-insulated ends.
Innovation Solution
A voice coil design with conductive foils attached to the coil bobbin, where non-insulated ends are wound along the foil surfaces and fixed with solder connections, allowing for easier and more secure film removal without exposing the ends, thus reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If films are removed precisely to avoid rust exposure, then reliability is improved, but manufacturing time increases
Solution Approach 1:
The conductive foils are attached to the coil bobbin before the coil winding is completed. This preliminary attachment allows the non-insulated ends to be immediately covered and protected, eliminating the need for precise film removal operations and reducing production time while maintaining reliability
Solution Approach 2:
Conductive foils are introduced as an intermediary element between the non-insulated coil ends and the environment. The foils serve as a protective barrier that prevents rust exposure without requiring precise film removal, thus resolving the contradiction between reliability and production time
2Reliability
If films are removed precisely, then rust exposure is prevented, but production costs increase
Solution Approach 1:
By attaching conductive foils to the coil bobbin before completing the winding process, the need for precise and time-consuming film removal operations is eliminated. This simplifies the manufacturing process and reduces production costs while maintaining coil lifetime through effective rust prevention
Solution Approach 2:
The conductive foils act as an intermediary protective layer that simplifies manufacturing. Instead of requiring precise film removal operations, the foils are simply attached to cover the non-insulated ends, reducing manufacturing complexity and costs while ensuring rust protection
3Ease of operation
If non-insulated ends are exposed, then electrical connection is achieved, but rust occurs reducing lifetime
Solution Approach 1:
The conductive foils are merged with the coil bobbin structure by attaching them before winding completion. This integration allows the foils to simultaneously serve as both the electrical connection medium and the protective covering for non-insulated ends, eliminating the need to expose the ends while maintaining electrical connectivity
Solution Approach 2:
Conductive foils serve as an intermediary that provides both electrical connection and rust protection. The foils are attached to the coil bobbin and extend to cover the non-insulated ends, allowing electrical connection to be achieved through the foil rather than direct exposure of the wire ends
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 design maintains voice coil quality by preventing rust and reducing production time, thereby enhancing the coil's lifetime and lowering production costs.
Implementation Method 1
electrically connecting and fixing each of the two ends in the wound state to the corresponding conductive foils
Data Source
AI summary
Two ends 5A, 5B of an electric wire 4 forming a coil 2 are made non-insulated by removing films. These two ends 5A, 5B are bent along surfaces of respective corresponding conductive foils 3A, 3B including the electric wire 4 following thereto in wounded states. Under such bent states, two ends 5A, 5B are compacted within the corresponding conductive foils 3A, 3B and are connected and fixed to the conductive foils 3A, 3B by solder welding and the like.