Wire Positioning Groove for Laser Welding Coil Components
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Solution Overview
Problem
Existing methods for connecting wires to metal terminals in coil components face challenges with positional displacement of wires during the temporary fixing and welding process, leading to potential connection defects and product defects.
Innovation Solution
A method involving a metal terminal with a positioning groove to securely position the wire, followed by a thermocompression bonding step using the insulating resin coating as an adhesive, and a laser welding step to ensure precise and stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a holding portion is folded to temporarily fix the wire to the receiving portion, then the wire is temporarily secured, but the position of the wire may be displaced
Solution Approach 1:
A positioning groove is introduced as an intermediary structure between the wire and the receiving portion. The groove receives and positions the wire before the holding portion is folded, serving as a mediator that ensures accurate wire positioning while the holding portion provides temporary fixation. This resolves the contradiction by adding a positioning function without compromising the temporary fixing reliability.
Solution Approach 2:
The positioning groove is formed in advance on the receiving portion before the wire is placed and temporarily fixed. This preliminary action of creating the groove structure allows the wire to be positioned accurately before the holding portion is folded, preventing position displacement during the temporary fixing process while maintaining reliable fixation.
2Ease of manufacture
If the holding portion is folded to sandwich the wire, then temporary fixation is achieved, but connection defects may occur due to position displacement
Solution Approach 1:
The positioning groove acts as an intermediary that guides and secures the wire in the correct position before the holding portion is folded. This ensures that when the holding portion sandwiches the wire, the wire remains properly positioned, preventing connection defects while maintaining the ease of temporary fixation through the folding action.
Solution Approach 2:
The positioning groove is prepared in advance to receive and position the wire correctly. This preliminary positioning action ensures that subsequent folding of the holding portion will securely fix the wire without causing position displacement, thereby maintaining both ease of manufacture and connection quality.
3Power
If laser welding is applied to melt and bond the wire and metal terminal, then electrical connection is achieved, but positional displacement during previous steps may cause connection defects
Solution Approach 1:
The positioning groove is formed in advance to receive and position the wire accurately before the welding process. The holding portion is also prepared in advance to provide temporary fixation. These preliminary actions ensure that the wire is correctly positioned before laser welding is applied, preventing connection defects while maintaining welding efficiency.
Solution Approach 2:
The positioning groove serves as an intermediary structure that ensures accurate wire positioning before welding. By providing a dedicated positioning feature, the groove mediates between the wire placement and the welding process, ensuring that the wire is in the correct position for high-precision laser welding without displacement.
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
Minimizes positional displacement of the wire, preventing connection defects and ensuring a reliable electrical connection between the wire and metal terminal.
Implementation Method 1
laser welding is applied. A laser beam is irradiated to the welding portion 11 so that the conductive wire portion 4 of the wire 3 and the welding portion 11 are melted to each other
Implementation Method 2
A liquefied molten portion is formed into a ball shape by surface tension
Implementation Method 3
a laser beam is irradiated to the insulating resin coating 5 for removing the insulating resin coating 5
Implementation Method 4
a thermocompression bonding step where the wire is adhered to the positioning groove using the melted insulating resin coating as an adhesive agent by applying heat and pressure to the wire positioned by being fitted in the positioning groove
Data Source
AI summary
A method of manufacturing a coil component including a step of welding a wire to a metal terminal by laser welding capable of making positional displacement of the wire only minimally occur. As a metal terminal, a metal terminal having a connecting portion on which a positioning groove for receiving and positioning a portion of the wire is formed is prepared. The wire is temporarily fixed to the connecting portion in a state where the wire is positioned by being fitted in the positioning groove, and the wire and the metal terminal are welded to each other by irradiating a laser beam. The positioning groove is preferably formed into a V shape in cross section.