Bobbinless Coil Shape Accuracy via Self-Biasing Guide Members
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Solution Overview
Problem
Bobbinless coils lack accuracy in shape due to the absence of a guiding bobbin and require excessive tape and steps for winding, leading to inefficiencies in conductor wire bonding.
Innovation Solution
A bobbinless coil design featuring disk-shaped guide members that abut on opposite ends of the conductor wire, with the conductor wire itself acting as a biasing member to maintain the coil shape, eliminating the need for a special biasing member and tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bobbin is used to guide the conductor wire during winding, then the coil shape accuracy is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent removes the traditional bobbin structure entirely, extracting only the essential guiding function. The conductor wire itself serves as the guiding element through its own elasticity, eliminating the need for separate guiding components and reducing overall device complexity while maintaining coil shape accuracy.
Solution Approach 2:
The conductor wire performs dual functions: it is both the material being wound and the guiding element that maintains the coil shape. The wire's own elastic properties enable it to self-guide during winding and self-maintain the cylindrical shape after winding, eliminating the need for external guiding structures.
2Stability of the object's composition
If tape with bonding layer is wound over the entire conductor wire length to maintain shape, then the coil shape stability is improved, but the quantity of material and manufacturing steps increase
Solution Approach 1:
The patent extracts and eliminates the tape bonding layer entirely, removing this additional material layer and the associated manufacturing steps. The conductor wire's inherent elasticity replaces the need for external bonding materials, achieving shape stability without adding material quantity or process complexity.
Solution Approach 2:
The conductor wire's own elastic properties provide the shape-maintaining function that would otherwise require external bonding materials. The wire naturally resists deformation and maintains its cylindrical coil shape through its inherent mechanical properties, eliminating the need for additional stabilizing materials.
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 design ensures accurate maintenance of the coil shape, reduces component count, and enhances electric current responsiveness by eliminating the bobbin and tape, while maintaining the exposed inner peripheral surface of the coil.
Implementation Method 1
a biasing member biasing the pair of guide members toward each other
Data Source
AI summary
A pair of disk-shaped guide members abut on opposite end surfaces in the axial direction of a conductor wire wound round into a coil shape by using a separable jig. The guide members are biased toward each other by engaging a part of the conductor wire with engaging portions formed at circumferences of the pair of guide members. Then, the jig is separated from the center of the conductor wire, thereby maintaining the coiled shape of the conductor wire to create a bobbinless coil having an exposed inner peripheral surface. In addition, the pair of disk-shaped guide members are biased toward each other by utilizing a part of the conductor wire, and therefore a special biasing member is not needed.