Wound Coil Compression via Jig Rotation for Inductance
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Solution Overview
Problem
Current methods for manufacturing coil components face challenges in achieving higher efficiency, reduced size, securing a cut margin, preventing defective exposure, and increasing magnetic material volume, particularly in low-current and high-current environments.
Innovation Solution
A method involving the use of a first and second jig to press a wound coil, applying pressure through a rotation mechanism to deform the coil, reducing its size while maintaining efficiency and securing a magnetic material margin, and preventing defective exposure by precise alignment and deformation techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used, then production is simpler, but manufacturing precision and coil alignment are insufficient leading to defective exposure
Solution Approach 1:
The pressing device is divided into multiple independent pressing units, each capable of pressing the coil at different positions. This segmentation allows precise control over coil compression at specific locations while maintaining overall device simplicity through modular design.
Solution Approach 2:
A pressing member acts as an intermediary between the actuator and the coil, enabling precise force transmission and positioning. The pressing member can be selectively positioned and activated to compress the coil at predetermined locations without requiring complex direct actuation mechanisms.
2Volume of moving object
If coil size is reduced to improve component density, then volume decreases, but cut margin becomes insufficient leading to defects
Solution Approach 1:
The coil is pressed and pre-formed to its final dimensions before the cutting process. This preliminary action ensures that the coil achieves its target size and shape with built-in margin for subsequent cutting operations, preventing defective exposure while maximizing space utilization.
Solution Approach 2:
The pressing process dynamically adjusts compression parameters (force, duration, positioning) to optimize the coil's final dimensions. By controlling the pressing parameters, the system ensures adequate cut margin is maintained even as coil size is reduced for higher density packaging.
3Quantity of substance
If magnetic material volume is increased to improve inductance, then inductance increases, but device size increases reducing mass production efficiency
Solution Approach 1:
The coil is nested within a magnetic material body that is formed in a single integrated structure. This nesting approach allows maximum magnetic material volume to be utilized within the available space, increasing inductance without requiring additional device volume or complex assembly steps that would reduce productivity.
Solution Approach 2:
The coil and magnetic material are combined into a single integrated component through the pressing process, eliminating separate assembly steps. This merging allows optimized magnetic material distribution around the coil for maximum inductance while maintaining a compact form factor suitable for high-volume manufacturing.
4Shape
If pressing force is increased to improve coil density, then coil compactness improves, but risk of defective exposure increases
Solution Approach 1:
Different pressing forces are applied to different regions of the coil based on local requirements. Critical areas receive higher force for compactness while other regions maintain lower force to preserve structural integrity and prevent defective exposure. This localized quality control optimizes the balance between density and reliability.
Solution Approach 2:
The pressing device incorporates cushioning mechanisms that prevent excessive force application. By designing the pressing system with built-in force limits and progressive compression stages, the system avoids over-compression that could cause coil damage or defective exposure while still achieving adequate compactness.
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
The method enables easy mass production with improved price competitiveness, reduced coil size, enhanced magnetic material volume, and prevention of defective exposure, thereby increasing inductance and efficiency in both low-current and high-current environments.
Implementation Method 1
pressing the wound coil includes bringing the first jig and the second jig into contact with each other by a first rotation of the first jig
Data Source
AI summary
A method for manufacturing a coil component includes: preparing a wound coil, a first jig and a second jig; disposing the wound coil on the first jig; and pressing the wound coil, wherein the pressing the wound coil includes bringing the first jig and the second jig into contact with each other by a first rotation of the first jig.