Thermally Protected Bobbin Assembly with Integrated Magnet Wire Termination
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Solution Overview
Problem
Traditional methods for connecting thermal protectors to magnet wire in bobbins are complex, costly, and time-consuming, involving splices and lead wires that complicate manufacturing and increase expenses.
Innovation Solution
A thermally protected bobbin assembly with a thermal protection body integrally connected to a magnet wire terminating feature of unitary one-piece construction, eliminating the need for intervening lead wires and allowing direct electrical connection through notches or serrations that wear away insulation to establish contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional splice and lead wire methods are used to connect thermal protectors to magnet wire, then thermal protection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the thermal protector body and the magnet wire terminating feature into a single integrated component. The thermal protector body (22) includes built-in receptacle portions (48) that directly receive and terminate magnet wire, eliminating the need for separate lead wires and splices. This merging of functions reduces manufacturing complexity while maintaining thermal protection reliability.
2Reliability
If traditional splice and lead wire methods are used to connect thermal protectors to magnet wire, then thermal protection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The integrated design allows the magnet wire to be directly inserted into the receptacle portions of the thermal protector body without requiring separate lead wire attachment steps. This eliminates multiple manual operations (stripping, splicing, crimping) and enables more efficient manufacturing processes.
Solution Approach 2:
The thermal protector body includes receptacle portions that automatically receive and secure the magnet wire ends through the spindle structure. The design enables self-termination of the magnet wire within the thermal protector body, reducing the need for additional manual assembly steps and improving manufacturing efficiency.
3Reliability
If traditional splice and lead wire methods are used, then thermal protection is achieved, but material costs and manufacturing steps increase
Solution Approach 1:
The patent integrates the thermal protector body with built-in magnet wire termination capabilities through receptacle portions. This eliminates the need for separate lead wires, splices, and associated materials, simplifying the manufacturing process and reducing material requirements while maintaining thermal protection functionality.
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 simplifies manufacturing, reduces material costs, improves reliability by eliminating the need for stripped lead wires, and enables full automation of the manufacturing process.
Implementation Method 1
a magnet wire wound onto a spindle of the thermally protected bobbin assembly such as to form an electromagnetic coil
Implementation Method 2
allowing direct electrical connection through notches or serrations that wear away insulation to establish contact
Data Source
Figure 1~2A
Figure 3~4
Figure 5~8
AI summary
The present invention is directed to a thermal protector (20) including a body (22) integrally connected to a magnet wire terminating feature (24). Additionally, a thermally protected bobbin (32) comprises a magnet wire (36) wound onto a spindle (34), and the thermal protector (20) including body (22) integrally connected to the magnet wire terminating feature (24). The magnet wire terminating feature (24) forms a connection with the magnet wire (36).