Braided Lead Wire Electromagnetic Coil Assembly
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Solution Overview
Problem
Electromagnetic coil assemblies face mechanical stress issues during assembly due to rigid dielectric materials, leading to wire fatigue and breakage, especially in high-temperature applications where conventional organic dielectrics fail to maintain insulation.
Innovation Solution
Incorporating braided lead wires that are mechanically and electrically coupled to the coiled magnet wire within a dielectric body, providing redundancy and flexibility to mitigate mechanical stress, and using inorganic dielectric materials for high-temperature applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid dielectric material is used to embed electromagnetic coil, then electrical insulation and position holding are improved, but mechanical stress on magnet wire increases leading to fatigue and breakage
Solution Approach 1:
A flexible buffer material is introduced as an intermediary between the rigid dielectric material and the magnet wire. This buffer material absorbs mechanical stress and prevents it from being transmitted to the magnet wire, while allowing the rigid dielectric to maintain its electrical insulation and position holding functions.
Solution Approach 2:
The patent changes the mechanical parameters of the embedding material by using a two-layer structure: a rigid dielectric layer for electrical insulation and a flexible buffer layer for stress absorption. This parameter differentiation allows simultaneous achievement of insulation reliability and mechanical stress resistance.
2Volume of moving object
If fine gauge magnet wire is used for electromagnetic coil, then device size is reduced, but mechanical fatigue and work hardening occur during assembly
Solution Approach 1:
The flexible buffer material is placed beforehand around the magnet wire before the rigid dielectric is applied. This cushioning layer prevents mechanical stress and work hardening from occurring during assembly operations, protecting the fine gauge wire while maintaining compact coil dimensions.
3Reliability
If aluminum magnet wire is used, then electrical conductivity is improved, but work hardening and breakage occur during assembly
Solution Approach 1:
The flexible buffer material serves as a protective intermediary that prevents mechanical stress from being applied to the aluminum magnet wire during assembly. This allows the use of aluminum wire for its superior electrical conductivity without suffering from its tendency to work harden and break under mechanical stress.
Data Source
AI summary
Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the electromagnetic coil assembly includes a body of dielectric material, a coiled magnet wire at least partially embedded within the body of dielectric material, a braided lead wire extending into the body of dielectric material to the coiled magnet wire, and a joint buried within the body of dielectric material and mechanically and electrically coupling the braided lead wire and the coiled magnet wire.