Adjustable Bobbin for Inductive Components
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Solution Overview
Problem
Conventional inductive components face challenges in adapting to varying properties and manufacturing tolerances, leading to inefficiencies and increased costs due to the need for multiple component types and complex production processes.
Innovation Solution
A bobbin design with adjustable guide devices allows for variable length adjustment, accommodating different winding lengths and core materials, enabling flexible adaptation to required properties without the need for new molds or tools, and enhancing magnetic and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fixed-length coil formers are used, then manufacturing precision can be maintained, but adaptability to different winding lengths and core materials is poor
Solution Approach 1:
The coil former is designed with an adjustable length mechanism, transforming from a fixed static structure to a dynamic one that can be adapted to different winding lengths and core materials. The guide devices allow the coil former to be extended or shortened as needed, providing versatility without requiring multiple different components.
Solution Approach 2:
A single coil former design serves multiple functions by accommodating various winding lengths and core material configurations. The adjustable guide devices enable the same coil former to be used across different applications, replacing the need for multiple specialized components.
2Adaptability or versatility
If multiple component types are produced to accommodate varying properties, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
One universal coil former design with adjustable guide devices replaces the need for multiple different component types. This single design can be configured to produce various inductive component properties by adjusting the guide device positions, simplifying manufacturing while maintaining versatility.
Solution Approach 2:
The physical parameters of the coil former (specifically its effective length) are made changeable through the adjustable guide devices. This allows the same base component to be configured for different electrical and magnetic properties by simply adjusting the guide device positions rather than manufacturing entirely different components.
3Manufacturing precision
If fixed-length coil formers are used, then device complexity is reduced, but ability to compensate for manufacturing tolerances is poor
Solution Approach 1:
The adjustable guide devices provide a dynamic mechanism that allows fine-tuning of the coil former length to compensate for manufacturing tolerances in windings and core materials. This dynamic adjustment capability enables precision compensation without requiring overly complex fixed structures.
Data Source
Figure 1a~1b
Figure 1c
Figure 2a~2b
AI summary
The bobbin (100) has two coil body portions (100a, 100b) respectively provided with two guiding elements (110a, 110b) that are in contact and slid together so that length of the coil body portions is adjustable along a longitudinal axis (LA). The guide elements are formed to define a reservoir (117) for accommodating a core material. The guide elements are formed to receive windings i.e. cantilevered windings. Side surfaces (115a, 115b) are formed laterally at the coil body portions as contact surfaces for attachment of core materials. An independent claim is also included for an inductive component.