Angled Floor Antenna Bobbins for Automated Winding
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Solution Overview
Problem
Conventional tilted antenna bobbin designs require significant labor and time for wrapping coil windings due to the parallel floor surface, which leads to inefficiencies in automation and uniformity of the coil assembly.
Innovation Solution
The design incorporates a bobbin with channels that have angled floors between 20° and 70° with respect to the central axis, allowing the tension on the wires to be absorbed orthogonally, reducing the likelihood of slippage and enabling easier automation of the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a parallel floor surface is used in conventional tilted antenna bobbin designs, then the structure is simple to manufacture, but significant labor and time are required for wrapping coil windings and automation is difficult
Solution Approach 1:
The patent applies asymmetry by changing the floor surface from a parallel (symmetric) configuration to an angled (asymmetric) configuration. The angled floor surface creates an asymmetric geometry that naturally guides the coil windings and facilitates automated wrapping processes, resolving the contradiction between automation capability and structural simplicity.
Solution Approach 2:
The patent introduces a new dimensional aspect by angling the floor surface at specific angles (e.g., 45 degrees) relative to the bobbin axis. This angular dimension provides a slope that guides the wire during winding, enabling automation while maintaining manufacturing feasibility through standard machining operations.
2Manufacturing precision
If a parallel floor surface is used in conventional tilted antenna bobbin designs, then the manufacturing process is straightforward, but the uniformity and efficiency of coil assembly deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-configuring the floor surface with a specific angle before the coil winding process begins. This pre-set angular geometry proactively guides the wire placement and tension distribution, ensuring uniform coil assembly without requiring complex manual adjustment during the winding process.
Solution Approach 2:
The patent changes the geometric parameter of the floor surface from parallel (0 degrees) to angled (e.g., 45 degrees). This parameter change fundamentally alters how the wire interacts with the bobbin during winding, improving uniformity and efficiency while remaining compatible with standard manufacturing capabilities.
3Productivity
If an angled floor surface is used, then labor and time for coil assembly are reduced, but the bobbin structure becomes more complex
Solution Approach 1:
The patent applies local quality by modifying only the floor surface geometry of the bobbin while leaving other components unchanged. The angled floor is a localized modification that provides significant productivity benefits without requiring a complete redesign of the entire bobbin structure, thus limiting the increase in overall complexity.
Data Source
AI summary
An antenna assembly includes a bobbin that provides a cylindrical body that defines an outer radial surface, an inner radial surface, and a central axis. One or more channels are defined on the outer radial surface, and each channel provides a first sidewall, a second sidewall opposite the first sidewall, a floor, and a pocket jointly defined by the first sidewall and the floor. A coil including one or more wires is wrapped about the bobbin and received within the one or more channels.