Choke Manufacturing via Automatic Winding and Pillar Core Assembly
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Solution Overview
Problem
Conventional choke manufacturing processes are labor-intensive and prone to inductance value variations due to manual winding and uneven adhesive application, leading to increased costs and reduced assembly stability.
Innovation Solution
The choke design incorporates an automatic winding process for the hollow coil, a core structure with a pillar and a second core body with an opening, and a material layer to enhance assembly stability and reduce inductance variations, allowing for adjustable inductance values using the same core and eliminating the need for precise adhesive control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual winding is used to wrap the wire around the toroidal core, then the wire can be precisely positioned, but the labor cost increases significantly
Solution Approach 1:
The patent replaces the manual mechanical winding process with an automatic winding machine that uses a rotating fixture to hold the toroidal core while the wire is automatically fed and wound around it. This substitution of manual mechanical operation with automated mechanical systems achieves both precise wire positioning and reduced labor costs.
2Ease of manufacture
If adhesive is used to assemble the combined core, then the core components can be joined together, but the inductance value varies due to uneven adhesive thickness
Solution Approach 1:
The patent extracts and eliminates the adhesive from the core assembly process. Instead of using adhesive to join the combined core components, the design uses a through-hole structure where a conductor passes through both core halves, which are then secured by a retaining ring or clamp. This removal of the adhesive element entirely eliminates the problem of uneven adhesive thickness causing inductance variation.
3Reliability
If a through-hole is added to the second core body for the pillar, then the assembly stability is improved, but the core structure becomes more complex
Solution Approach 1:
The patent segments the core into two separate halves (first core body and second core body) with a through-hole in the second core body. The pillar with the hollow coil is inserted through this through-hole, and the two core halves are then assembled together to enclose the pillar. This segmentation allows for improved assembly stability through precise positioning while keeping each individual core half relatively simple in structure.
Data Source
AI summary
A method to form a choke is disclosed, wherein the method comprises: encapsulating a hollow coil by a molding body; forming a first core, wherein the first core comprises a pillar; and disposing at least one first portion of the pillar inside the encapsulated hollow coil. The method avoids the overflow or vertical flow issue during a molding process for encapsulating a coil that has been wound on a core already.