Air-Core Coil Lead Routing to Reduce Actuator Magnet Gap
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Solution Overview
Problem
In magnetic drive mechanisms, the need to extend the coil wire along the surface of the winding part to connect it with a power feeding circuit board increases the gap space between the coil and the magnet, reducing the thrust and requiring a larger device size.
Innovation Solution
The use of a coil structure with a first and second air core coil, where the first inner side lead-out wire is extended to the inner peripheral side and the first and second outer side lead-out wires are extended to the outer peripheral side, allowing connection without surface extension, and an adhesive layer for integration and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil wire is extended along the surface of the winding part to connect with the power feeding circuit board, then the connection is achieved, but the gap space between the coil and magnet becomes large
Solution Approach 1:
The patent changes the routing dimension of the coil wire from surface-level (2D plane along the winding part surface) to through-hole (3D space through the center hole). The coil wire passes through the center hole of the winding part to reach the outer peripheral side, eliminating the need to extend along the surface and thereby reducing the gap between the coil and magnet.
2Force
If the gap space between the coil and magnet is reduced to increase thrust, then the device size is reduced, but the coil wire cannot be connected to the power feeding circuit board
Solution Approach 1:
The patent resolves this contradiction by routing the coil wire through the center hole (utilizing the Z-axis dimension through the winding part) rather than along the surface (X-Y plane). This allows the gap between coil and magnet to be minimized for increased thrust while the wire still reaches the power feeding circuit board through the central passage.
3Ease of manufacture
If the coil wire is extended along the surface of the winding part, then the connection is achieved, but the device size increases
Solution Approach 1:
The patent reduces device size by changing the wire routing from surface extension (increasing lateral dimensions) to through-hole routing (utilizing the central vertical passage). The coil wire passes through the center hole to reach the outer peripheral side, eliminating the need for additional lateral space and thereby compacting the overall device volume.
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 reduces the gap between the coil and magnet, increasing thrust and reducing device size, while ensuring secure electrical connections and preventing lead-out wires from escaping during vibration.
Implementation Method 1
a magnetic drive mechanism having the magnet and the coil to relatively move the movable body and the support body
Data Source
AI summary
An actuator includes a movable body having a magnet, a support body having a coil, and a power feeding board with which two lead-out wires extended from a winding part of the coil are connected. The coil includes a first air core coil and a second air core coil. The first air core coil has a first winding part, a first inner side lead-out wire, and a first outer side lead-out wire. The second air core coil has a second winding part whose winding direction is the same as the first winding part and which is overlapped with the first winding part, a second inner side lead-out wire which is extended from the second winding part and whose tip end portion is electrically connected with a tip end portion of the first inner side lead-out wire, and a second outer side lead-out wire extended from the second winding part.