Asymmetric Drum Core Ridge Design for Wire Winding
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Solution Overview
Problem
Existing drum cores with uniform side surfaces and ridge portions face increased breaking or cracking risk due to enhanced holding forces required during wire winding, as they are held by jigs with different shapes, which can exert uneven forces.
Innovation Solution
A drum core design featuring first and second flange portions with differently shaped ridge portions, where the first ridge portion has a larger dimension or radius of curvature than the second, and optionally third and fourth ridge portions with smaller dimensions or curvatures, to distribute holding forces more evenly and reduce cracking risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the two side surfaces and ridge portions have the same shape for manufacturing convenience, then the drum core can be efficiently manufactured without alignment, but the drum core is at increased risk of breaking or cracking when held by jigs with different shapes during wire winding
Solution Approach 1:
The patent applies asymmetry by making the first ridge portion and second ridge portion have different shapes. Specifically, the first ridge portion has a larger dimension or radius of curvature than the second ridge portion. This asymmetric design allows the drum core to be held by jigs with different shapes during wire winding, distributing holding forces more evenly and reducing the risk of breaking or cracking while maintaining manufacturing efficiency
Solution Approach 2:
The patent applies local quality by giving different properties to different parts of the drum core. The first ridge portion is designed with a larger dimension or radius of curvature compared to the second ridge portion, allowing each ridge portion to be optimized for its specific function when contacted by differently shaped jigs during the wire winding process
2Force
If the dimension of the second side surface in the axial direction is increased to enhance holding force, then the contact area with the jig is increased, but the dimension of the second ridge portion must be reduced which may increase cracking risk
Solution Approach 1:
The patent resolves this contradiction by making the first ridge portion and second ridge portion asymmetric. The first ridge portion has a larger dimension or radius of curvature than the second ridge portion, allowing each ridge portion to be optimized for its specific contact conditions with differently shaped jigs, thereby maintaining sufficient holding force while reducing cracking risk
Data Source
AI summary
A drum core includes a core portion that extends in an axial direction, first and second flange portions respectively disposed at first and second ends of the core portion in the axial direction, and first and second terminal electrodes respectively disposed at the first and second flange portions. The first flange portion includes a bottom surface that is substantially parallel to the axial direction and on which the first terminal electrode is disposed, an outer end surface that is substantially perpendicular to the axial direction and that faces outward away from the core portion, and a first ridge portion and a second ridge portion respectively disposed at a first end and a second end of the outer end surface in a width direction substantially parallel to the bottom surface and the outer end surface, and the first ridge portion and the second ridge portion have different shapes.