Wound Coil Resin Coating Shape Accuracy via Elastic Holding Jig
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Solution Overview
Problem
Existing methods for manufacturing wound coils with a coating resin fail to achieve consistent shape accuracy and stability due to the elastic force of component housing parts causing shape loss and variability in the appearance configuration.
Innovation Solution
A method involving a holding jig with an elastic inner surface to securely position the wound coil, allowing the coating resin to be supplied and cured in a controlled manner, ensuring it covers the upper and side portions of the winding core without flowing, and removing excess resin to maintain shape accuracy and simplify the core design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wound coil element is pressed into the component housing part with the coating resin dried in contact with a finger, then the coating resin is formed into a shape corresponding to the housing part, but the shape of the coating resin is lost by the elastic force of the housing part, failing to form the desired shape
Solution Approach 1:
The patent applies preliminary action by pre-forming the coating resin into the desired shape before it sets, using a mold or shaping tool. The coating resin is applied and shaped while still in a workable state, allowing it to be formed into the precise configuration needed before the elastic force of the housing part can cause deformation. This ensures the coating resin achieves the target shape accuracy before stability becomes an issue.
Solution Approach 2:
The patent employs preliminary anti-action by applying a constraint or counterforce to prevent the elastic force of the housing part from deforming the coating resin. This could involve using a rigid mold or support structure that counteracts the elastic rebound of the housing part, thereby maintaining the intended shape of the coating resin despite the opposing elastic force.
2Ease of manufacture
If multiple relief parts are provided on the flanges to retain the coating resin, then the coating resin can be relieved when shaped, but the appearance configuration is not stable and varies depending on the multiple relief parts
Solution Approach 1:
The patent applies the taking out principle by removing the relief parts from the flange structure. Instead of incorporating multiple relief parts that cause variability, the design extracts this feature entirely and replaces it with an alternative approach to coating resin retention, such as a continuous retaining structure or a different retention mechanism that does not compromise appearance consistency.
Solution Approach 2:
The patent applies local quality by providing a single, well-defined relief part or retention structure at a specific location rather than multiple relief parts distributed across the flanges. This localized approach ensures uniform appearance by concentrating the retention function in one consistent position, eliminating the variability introduced by multiple distributed relief parts.
3Manufacturing precision
If the coating resin is supplied into the holding hole with a gap between the inner surface and the coil, then the coating resin covers the upper and side portions of the winding core, but the coating resin may flow away downwardly from the gap
Solution Approach 1:
The patent applies parameter changes by adjusting the viscosity of the coating resin to a level that prevents it from flowing away downwardly from the gap while still allowing it to cover the upper and side portions of the winding core. By controlling the rheological parameters of the resin, the system achieves both adequate coverage and flow control, eliminating the harmful effect of excessive resin flow.
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 method efficiently produces wound coils with improved shape accuracy and consistent appearance, reducing the need for relief parts on flanges and enhancing electrical characteristics like magnetic flux shielding, while increasing productivity and dimensional accuracy.
Implementation Method 1
pressing the wound coil element in a holding hole of a holding jig, the holding hole having an inner surface made of an elastic material
Implementation Method 2
curing the supplied coating resin, with the wound coil element held in the holding jig
Data Source
AI summary
A method for manufacturing a wound coil which has a stable appearance configuration with improved shape accuracy of a coating resin formed on the wound coil. A wound coil element is pressed into a holding jig including an elastic holding hole, and held therein such that an upper end of a coil is level with or lower than an upper end of the holding hole, and a gap G is present between an inner surface of the holding hole and the coil. Next, a flowable coating resin is supplied into the holding hole holding the wound coil element such that the coating resin is held without flowing away downwardly from the gap G, and the upper end 16a of the coil is buried in the coating resin. Next, the supplied coating resin is subjected to curing, thereby forming a wound coil.