Electromagnetic Actuator With Injection-Molded Coil
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Solution Overview
Problem
Existing electromagnetic actuators, such as voice coil motors, face complexity in interconnection structures and limitations in increasing the number of windings due to the size constraints of the coil placement area, which hinders the achievement of desired thrust while maintaining a reduced thickness.
Innovation Solution
The electromagnetic actuator features a base member with a coil formed as an injection molded circuit component and a magnet secured to a driving frame, allowing for a simplified interconnection structure and increased winding density through multilayer interconnection layers, enabling the desired thrust with reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a flat coil is wound on a circuit board surface, then the thickness is reduced, but the number of windings is limited and desired thrust cannot be achieved
Solution Approach 1:
The patent transitions from planar winding (2D) to three-dimensional winding within a cylindrical bore (3D). The coil is wound around a cylindrical core within a hole portion of the circuit board, enabling multiple layers of windings in the vertical dimension while maintaining overall thinness. This dimensional transition allows significantly increased winding count without proportionally increasing device thickness.
Solution Approach 2:
The coil is nested within a cylindrical bore or hole portion of the circuit board structure. The winding passes through the hole portion multiple times, with each pass forming a layer nested within the vertical space of the bore. This nesting approach maximizes the use of available vertical space for windings while keeping the overall footprint compact.
2Force
If the coil placement area is made large to increase windings, then thrust is improved, but the device size increases
Solution Approach 1:
Instead of expanding the planar area for coil placement, the invention exploits the vertical dimension by creating a three-dimensional winding structure within a cylindrical bore. The coil makes multiple passes through the vertical space of the bore, allowing high winding density without increasing the horizontal footprint of the device.
Solution Approach 2:
The circuit board contains a hole portion or cylindrical bore that acts as a void space utilized for three-dimensional coil winding. This porous structure in the circuit board allows the coil to be routed through the vertical dimension, effectively increasing winding capacity without consuming additional planar area.
3Adaptability or versatility
If a flexible circuit is used to lead out interconnection from the movable circuit board, then movement is absorbed, but the interconnection structure becomes complex
Solution Approach 1:
The coil and its interconnection circuit are merged into a single integrated component formed directly on the circuit board. The coil is constructed using conductive traces that are part of the circuit board's interconnection system, eliminating the need for separate flexible circuits or additional interconnection components. This integration simplifies the overall interconnection structure while maintaining movement capability.
Solution Approach 2:
The circuit board serves multiple functions: it provides the structural substrate, contains the interconnection circuit for electrical connections, and incorporates the coil winding structure within its hole portion. This multi-functionality eliminates the need for separate dedicated components for each function, reducing overall system complexity.
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 configuration simplifies the interconnection structure, increases the number of windings, and achieves the desired thrust while maintaining a reduced thickness, enhancing the performance and miniaturization of electromagnetic actuators.
Implementation Method 1
a coil that is secured to the base member; and a magnet that is secured to the driving frame, wherein: the coil is formed as an injection molded circuit component
Implementation Method 2
drive the movable element in respect to the stationary element through thrust (Lorentz forces) that acts between the magnet and the coil when power is applied to the coil
Data Source
AI summary
Provided is an electromagnetic actuator for which the wiring structure thereof can be simplified, for which the thickness thereof can be reduced, and with which a desired drive force can be attained. An electromagnetic actuator is provided with: a base member; a drive frame that is supported so as to be movable in relation to the base member; a coil that is fixed to the base member; and a magnet that is fixed to the drive frame. The coil is formed as an injection-molded circuit part, and the base member has formed thereon a circuit that connects to the coil.