Bobbin With Crushable Ribs For E-Core And I-Core Assembly
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Solution Overview
Problem
The existing methods for assembling magnetic components with E-cores and I-cores require additional steps and materials, such as tape or glue, to secure the cores together, increasing labor and material costs.
Innovation Solution
A bobbin with a passageway and crushable ribs is used to securely hold the E-core and I-core in place without the need for taping or gluing, utilizing frictional engagement to maintain the cores' spatial relationship.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tape or glue is used to secure the cores together, then the cores are held in place during assembly, but additional steps and materials are required, increasing labor and material costs
Solution Approach 1:
The bobbin structure performs the securing function itself through its geometric features (channel wall and passageway ribs) rather than requiring external tape or glue. The crushable ribs deform under the middle leg's insertion force to create frictional engagement, enabling the bobbin to self-secure both cores without additional materials or steps.
Solution Approach 2:
The crushable passageway ribs act as an intermediary mechanism between the middle leg and the bobbin body. These ribs transfer and amplify the insertion force into radial frictional forces that secure the middle leg, while also serving as a mechanical interface that eliminates the need for separate securing materials.
2Stability of the object's composition
If tape or glue is used to secure the cores, then the cores remain fixed during assembly, but material costs and assembly time increase
Solution Approach 1:
The crushable ribs are pre-configured in the bobbin structure before assembly begins. During assembly, the middle leg's insertion automatically triggers the rib deformation and frictional engagement mechanism, performing the securing action as part of the core insertion process itself rather than as a separate subsequent step.
Solution Approach 2:
The patent merges the core insertion operation with the core securing operation into a single integrated action. The same motion that inserts the middle leg into the passageway also activates the frictional engagement mechanism, combining two previously separate steps (insertion and securing) into one simultaneous action.
3Reliability
If additional securing materials like tape or glue are used, then the cores are restrained properly, but the manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the need for external securing materials (tape, glue) by incorporating the securing function directly into the bobbin structure. The geometric features of the bobbin itself provide the restraint mechanism, removing the requirement for additional consumable materials.
Solution Approach 2:
The crushable ribs are designed as sacrificial, disposable elements within the bobbin structure. They are intentionally made deformable and are consumed during the assembly process through controlled deformation, providing a low-cost alternative to expensive securing materials while maintaining reliability.
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 method reduces labor and material costs by eliminating the need for additional securing steps and materials, while ensuring a stable assembly of the magnetic components.
Implementation Method 1
The middle leg is inserted into the passageway from the second end flange and crushes the passageway ribs to cause the middle leg to be frictionally engaged with the passageway ribs and thereby retained in the passageway
Implementation Method 2
The first facing surface of the I-core is spaced apart from the end surface of the middle leg of the E-core by the selected distance to form a magnetic gap. The friction of the first facing surface of the I-core against the first end flange and the friction of a parallel second facing surface of the I-core against the inner surface of the channel wall retain the I-core in a fixed spatial relationship with the outer legs and with the middle leg of the E-core.
Data Source
AI summary
A magnetic assembly includes a bobbin having at least first and second end flanges. The bobbin includes a channel wall displaced from the first end flange to from a channel therebetween. The channel receives and frictionally engages an I-core to retain the I-core in the channel. The bobbin includes a passageway that receives a middle leg of an E-core. The passageway includes a plurality of longitudinal ribs that extend from the first end flange toward the second end flange. The ribs are tapered with respect to the inner wall of the passageway. The middle leg of the E-core crushes the ribs. The frictional engagement of the crushed ribs with the middle leg retains the middle leg in the passageway. No taping, gluing or other additional step is required to assemble the bobbin and the two cores.