Multi-Part Bobbin Assembly for Pre-Wound Magnetic Coils
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Solution Overview
Problem
Conventional multi-part bobbins used in magnetic components are cumbersome and complicated to assemble, often requiring additional gluing steps.
Innovation Solution
A magnetic component with a multi-part bobbin featuring holding parts with cylindrical portions that form a form-fit connection, allowing for easy assembly and reduced manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional multi-part bobbins are used to enable edge-wise winding, then the coil can be pre-wound on a separate device, but the assembly becomes cumbersome and complicated requiring additional gluing steps
Solution Approach 1:
The bobbin is divided into multiple separate parts (first bobbin part and second bobbin part) that can be assembled together. This segmentation allows the coil to be pre-wound on a separate device and then attached to the assembled bobbin structure, enabling edge-wise winding while maintaining manageable assembly complexity through modular design
Solution Approach 2:
The cylindrical portion of one bobbin part is inserted into a corresponding cavity in the other bobbin part, creating a nested arrangement. This nesting provides inherent mechanical alignment and positioning, eliminating the need for additional gluing steps while maintaining the multi-part structure required for edge-wise winding
2Adaptability or versatility
If conventional multi-part bobbins are used to enable edge-wise winding, then the coil can be pre-wound on a separate device, but additional gluing steps are required
Solution Approach 1:
The cylindrical portion of one bobbin part is inserted into a corresponding cavity in the other bobbin part, creating a nested arrangement. This nesting provides inherent mechanical alignment and positioning, eliminating the need for additional gluing steps while maintaining the multi-part structure required for edge-wise winding
Solution Approach 2:
The nested cylindrical portion and cavity structure provides self-alignment and self-positioning during assembly. The geometry of the nested parts ensures proper positioning without requiring external alignment tools or additional fastening operations, reducing manufacturing steps
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
The solution enables a magnetic component that is easier to assemble and requires fewer manufacturing steps, improving efficiency and reducing the risk of assembly errors.
Implementation Method 1
at least one of the holding parts comprises a cylindrical portion inserted into, along a longitudinal axis of the winding unit, at least one winding unit so as to be surrounded thereby. Further, said cylindrical portion is in contact and attached to a separate holding part via a form-fit connection
Data Source
AI summary
The application concerns a magnetic component comprising a multi-part bobbin and at least one winding unit, the multi-part bobbin further comprising a plurality of holding parts configured to hold the at least one winding unit, wherein the at least one winding unit is pre-wound and comprises one or more coil winding turns, wherein at least one of the holding parts comprises a cylindrical portion inserted into, along a longitudinal axis of the winding unit, at least one winding unit so as to be surrounded thereby, and wherein said cylindrical portion is in contact and attached to a separate holding part via a form-fit connection.