Annular Core Coil Assembly With Fewer Joints for Lower Resistance
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Solution Overview
Problem
Inductors with annular magnetic cores and coils formed by joining multiple coil pieces and substrates experience increased resistance due to additional connection portions, which hinder efficient current flow.
Innovation Solution
The method involves bending a second coil piece to cover the end surface of an annular magnetic core, eliminating unnecessary connection portions by forming a continuous coil around the core's internal, external, and end surfaces, and joining the coil pieces with a weld section made from the same metal material to reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coil is formed by joining multiple coil pieces and a substrate, then the coil can be manufactured with modular components, but the resistance value of the coil increases due to additional connection portions
Solution Approach 1:
The patent merges multiple coil pieces into a single continuous coil structure that is directly wound around the magnetic core, eliminating the need for separate substrates and connection portions. This combining approach reduces the total number of connection points and eliminates interfaces between dissimilar metals, thereby reducing the overall resistance value while maintaining modular manufacturing benefits through the single-piece coil design
2Device complexity
If multiple coil pieces are joined together, then the coil can be assembled from separate components, but interfaces between dissimilar metals are created which increase resistance
Solution Approach 1:
The patent applies homogeneity by ensuring that the entire coil is made from the same metal material throughout, eliminating interfaces between dissimilar metals. The coil is formed as a single continuous piece of uniform material that is directly wound around the magnetic core, preventing resistance increases that would occur at material interfaces
3Ease of manufacture
If connection portions are added to join coil pieces, then the coil can be constructed from multiple segments, but the number of connection portions increases which hinders efficient current flow
Solution Approach 1:
The patent ensures continuity of useful action by creating a single continuous coil structure with no interruption or connection portions. The coil is wound as one unbroken piece directly around the magnetic core, allowing current to flow efficiently without encountering resistance at connection points, thereby maintaining continuous and efficient current flow throughout the entire coil
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 decreases the number of connection points, thereby reducing the resistance value of the coil and preventing interfaces between dissimilar metals, enhancing the coil's efficiency and ease of formation.
Implementation Method 1
the joint surface of the second coil piece and the joint portion of the first coil piece are joined by a weld section formed by melting the joint surface and the joint portion
Data Source
AI summary
An inductor includes an annular core, and a first coil and a second coil which are wound around the core. The core has an internal surface, an external surface, a first end surface, and a second end surface. The first coil and the second coil include a first coil piece having a length of one turn and a second coil piece having a length of one turn. The first coil piece and the second coil piece surround the internal surface, the first end surface, the external surface, and the second end surface of the core. The first coil piece has, at its tip, a joint portion to be joined to the second coil piece, and the second coil piece has, at its tip, a joint surface to be in contact with the joint portion. Thus, the resistance value of the coil is reduced.