Annular Core Inductor Coil Layout for Thick-Wire Stress Relief
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Solution Overview
Problem
Inductive components with annular cores face mechanical stress during winding, especially with thicker wires, leading to potential damage and increased production costs due to the need for durable housings that can absorb tension forces without deforming or passing them to the core.
Innovation Solution
The use of U-shaped conductor sections with mechanically and electrically connected limbs, fitted around a ring-shaped soft magnetic core, allows for the formation of a coil with reduced tension on the core, enabling the use of thicker wires without deforming the housing or core, and employing a connection technology that minimizes stress and maintains electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If thicker wires are used for coil winding, then current carrying capacity is improved, but mechanical stress on the annular core increases leading to potential damage
Solution Approach 1:
The coil is divided into two electrically conductive sections with U-shaped configurations. Each section has a first limb and a second limb that are connected through the core, distributing the mechanical stress of thick wire winding across multiple segments rather than concentrating it in a single continuous winding process.
Solution Approach 2:
The conductor sections are configured in three-dimensional U-shapes with curved first limbs that project away from the basic U-shape plane. This spatial arrangement allows the thick wires to be routed in multiple dimensions, reducing linear tension forces on the core while maintaining electrical connectivity.
2Strength
If durable plastic housings with increased wall thickness are used, then mechanical strength to absorb winding forces is improved, but housing volume and production costs increase
Solution Approach 1:
The coil winding process is segmented into two separate conductive sections that are fitted independently onto the core. This segmentation reduces the total tension force applied at any single point during winding, allowing standard thickness housings to suffice without requiring increased wall thickness for structural support.
Solution Approach 2:
The conductor sections utilize curved geometries and projected limbs that change the mechanical parameters of force distribution. The curved first limb and projected end configuration transforms linear tension into distributed radial and tangential forces, reducing peak stress on both the core and housing structure.
3Force
If multi-conductor cables are used for coil, then distribution of tension force is improved, but high-frequency behavior deteriorates due to higher capacities between windings
Solution Approach 1:
Instead of using multi-conductor cables that create parallel capacitance paths, the invention segments the coil into two series-connected U-shaped conductive sections. This segmentation eliminates the capacitive coupling issues inherent in multi-conductor cables while still distributing mechanical tension forces through the geometric configuration of the sections.
Solution Approach 2:
Rather than distributing conductors in parallel as in multi-conductor cables, the invention connects the two U-shaped sections in series through the core. This inverted connection topology achieves force distribution through spatial geometry rather than electrical parallelism, avoiding the harmful capacitive effects at high frequencies.
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 solution enables the use of thicker wires while maintaining core stability and compatibility with existing plastic housings, achieving effective suppression of common-mode interference up to higher frequencies and reducing production costs by minimizing the number of connection points and materials used.
Implementation Method 1
an inductive effect that can be used, for example, for suppressing common-mode interference
Data Source
AI summary
An inductive component, which has an annular core having a core cross section and made of a soft-magnetic material and a coil surrounding the core is provided. The coil is composed of two electrically conductive sections. The sections each have a basic U shape with two limbs, of which the first limb is longer than the second limb and the first limb is curved and towards the end of same projects away from a plane defined by the basic U shape. The sections are pushed onto the core next to one another so that the basic U shape of each section surrounds the core cross section on three sides. The first limb of a section is mechanically and electrically connected to the second limb of the other section. A method for producing a component of this kind is also described.