Multi-Part Bobbin Assembly for Pre-Wound Magnetic Components
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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 design featuring a multi-part bobbin with holding parts configured to securely attach pre-wound winding units via a form-fit connection, such as snap-fit or twist-and-lock, allowing for easy assembly and reduced manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-part bobbins are used to hold pre-wound coil units, then the magnetic component can be manufactured with separated winding and bobbin production processes, but the assembly process becomes cumbersome and complicated requiring additional gluing steps
Solution Approach 1:
The bobbin is divided into multiple separate parts (first bobbin part, second bobbin part, etc.) that can be manufactured independently and then assembled around the pre-wound coil units. This segmentation allows the winding process to be completed separately before bobbin assembly, enabling flexible manufacturing while maintaining manageable assembly complexity through the form-fit connection design.
Solution Approach 2:
The bobbin parts are designed to be nested around the pre-wound coil units, with each bobbin part surrounding the coil unit in a concentric arrangement. The cylindrical portions of the bobbin parts are inserted along the longitudinal axis of the coil units, creating a nested structure that simplifies assembly by eliminating the need for additional fastening steps.
2Device complexity
If multiple separate holding parts are used to surround the winding unit, then the bobbin can be assembled in simple steps via form-fit connection, but the number of separate components increases
Solution Approach 1:
The bobbin is divided into multiple separate parts (first bobbin part, second bobbin part, etc.) that can be manufactured independently and then assembled around the pre-wound coil units. This segmentation allows the winding process to be completed separately before bobbin assembly, enabling flexible manufacturing while maintaining manageable assembly complexity through the form-fit connection design.
3Ease of manufacture
If the cylindrical portion is inserted along the longitudinal axis of the winding unit, then the assembly process is simplified, but the holding part requires precise dimensional matching for form-fit connection
Solution Approach 1:
The coil units are pre-wound to the final specifications before the bobbin parts are assembled around them. This preliminary winding action ensures that the coil units have their final dimensions and shape, allowing the bobbin parts to be designed with form-fit connections that match these predetermined dimensions, thereby simplifying the subsequent assembly process.
Solution Approach 2:
The form-fit connection design incorporates dimensional parameters that allow for easy assembly. The cylindrical portions of the bobbin parts are designed with specific diameters and lengths that correspond to the dimensions of the pre-wound coil units, creating a snap-fit or form-fit connection that requires minimal assembly force and precision.
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 design facilitates easy and efficient assembly of magnetic components with reduced complexity and manufacturing time, while maintaining structural integrity and electrical insulation.
Implementation Method 1
said cylindrical portion being in contact and attached to a separate holding part via a form-fit connection
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention concerns a magnetic component (1) comprising a multi-part bobbin (2) and at least one winding unit (3), the multi-part bobbin (2) further comprising a plurality of holding parts (4) configured to hold the at least one winding unit (3), wherein the at least one winding unit (3) is pre-wound and comprises one or more coil winding turns, wherein at least one of the holding parts (4) comprises a cylindrical portion (5) inserted into, along a longitudinal axis (6) of the winding unit (3), at least one winding unit (3) so as to be surrounded thereby, and wherein said cylindrical portion (5) is in contact and attached to a separate holding part via a form-fit connection (70).