Electromagnetic Coils with Ceramic Bobbin and Siloxane Resin
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Solution Overview
Problem
Conventional electromagnetic coils fail to withstand harsh environments such as extreme temperatures and high vibration, leading to functional failures, and existing solutions are costly and inefficient, making them unsuitable for aerospace applications.
Innovation Solution
The development of electromagnetic coils featuring a ceramic bobbin, a coiled conductor with a siloxane polymer resin mixed with metal oxide, and an overwind of glass fiber yarn, using Commercial Off the Shelf (COTS) wire with coatings like aluminum oxide and silicon dioxide, which are cost-effective and maintain a high packing factor, allowing efficient operation in harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional organic insulation is used on coil wires, then manufacturing is simple and cost-effective, but the coil fails under extreme temperature exposure
Solution Approach 1:
The patent changes the chemical composition parameters of the insulation material from organic to inorganic materials (such as magnesium oxide, aluminum oxide, or silicon oxide coatings). This parameter change enables the insulation to withstand temperatures above 300°C while maintaining manufacturing simplicity through direct wire coating processes without complex preprocessing steps
Solution Approach 2:
The patent uses composite material structures where inorganic insulation coatings are applied over conductive wire cores. The combination of metal wire with ceramic-like inorganic coatings creates a composite that achieves both high-temperature resistance and electrical conductivity, resolving the contradiction between reliability under heat and ease of manufacture
2Reliability
If wire is wrapped with impregnated tape before winding, then temperature resistance improves, but packing factor decreases and weight increases
Solution Approach 1:
The patent changes the insulation application method from external tape wrapping to direct inorganic coating on the wire surface. This parameter change eliminates the need for additional wrapping layers, maintaining tight packing of wire turns and reducing overall coil weight while achieving equivalent or superior temperature resistance
Solution Approach 2:
The patent extracts the insulation function from a separate tape-wrapping step and integrates it directly into the wire manufacturing process through pre-applied inorganic coatings. This extraction eliminates the need for additional protective layers during winding, improving packing factor and reducing weight
3Reliability
If special preprocessing of conductor is performed, then temperature resistance improves, but manufacturing time and cost increase
Solution Approach 1:
The patent applies inorganic insulation coatings to the wire in advance during wire manufacturing, before the coil winding process. This preliminary action ensures temperature resistance is built into the wire itself, eliminating the need for time-consuming preprocessing steps in the coil manufacturing process and improving overall productivity
Solution Approach 2:
The patent merges the insulation application process with the wire manufacturing process, combining two separate operations (wire drawing and insulation coating) into a single integrated production line. This merging eliminates intermediate handling and preprocessing steps, reducing manufacturing time and cost while ensuring consistent temperature resistance
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 coils effectively withstand temperatures up to 300°C or 400°C, maintaining efficiency and reducing weight, while being cost-effective and avoiding the need for special preprocessing steps, thus suitable for aerospace applications.
Implementation Method 1
a potting resin applied to the coiled conductor during winding wherein, the resin is a siloxane polymer mixed with a metal oxide
Implementation Method 2
a bobbin made entirely of ceramic; a coiled conductor wrapped around the bobbin
Data Source
AI summary
An electromagnetic coil that can withstand high temperatures and operate efficiently and methods of making the same are provided. In preferred embodiments the electromagnetic coil comprises: a bobbin made entirely of ceramic; a coiled conductor wrapped around the bobbin; a potting resin applied to the coiled conductor during winding wherein, the resin is a siloxane polymer mixed with a metal oxide or a cyanate ester; and an overwind made of glass fiber yarn.