Choke Coil Terminal Apertures for Dimensional Variance Compensation
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Solution Overview
Problem
The existing method for manufacturing choke coils requires multiple manual stages and often results in significant dimensional variance between terminal members, necessitating complex machining operations.
Innovation Solution
The method involves forming apertures in the terminal members of the choke coil by bending an elongated piece of conducting material to compensate for lateral and longitudinal dimensional variances, eliminating the need for machining and simplifying assembly by using apertures as pivot points and adjustment slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining operations are used to form apertures in terminal members, then manufacturing precision can be achieved, but device complexity and manufacturing time increase due to multiple stages
Solution Approach 1:
The patent combines the aperture formation operation with the terminal member forming operation by using bending during the same manufacturing stage. Instead of separately machining apertures after forming terminal members, the apertures are created through bending the elongated piece during the initial forming process, merging two operations into one and eliminating complex machining stages.
Solution Approach 2:
The patent changes the method of aperture formation from mechanical machining to plastic deformation through bending. This parameter change in the forming mechanism allows apertures to be created during the terminal member forming process itself, reducing manufacturing stages while maintaining the required precision through controlled bending operations.
2Adaptability or versatility
If multiple manual stages are used for manufacturing choke coil, then flexibility in manufacturing can be maintained, but productivity decreases and dimensional variance increases
Solution Approach 1:
The patent merges multiple manual stages into integrated forming operations where terminal members and apertures are created in the same process step. This consolidation eliminates sequential manual operations, significantly improving productivity while maintaining manufacturing flexibility through the inherent adaptability of the bending process.
Solution Approach 2:
The patent performs preliminary forming of terminal members and apertures during the initial elongated piece formation, before final assembly. This preliminary action allows dimensional adjustments to be built into the structure itself, reducing the need for subsequent manual adjustments and improving overall manufacturing efficiency.
3Manufacturing precision
If identical rectangular apertures are machined in terminal members, then consistent manufacturing can be achieved, but lateral and longitudinal dimensional variances cannot be compensated
Solution Approach 1:
The patent introduces asymmetric aperture configurations where the first terminal member has a first aperture and the second terminal member has a second aperture with different orientations. The first aperture compensates for lateral dimensional variance while the second aperture compensates for longitudinal dimensional variance, allowing the structure to adapt to dimensional variations while maintaining manufacturing consistency.
Solution Approach 2:
The patent applies different aperture characteristics to different locations of the terminal members. Instead of using identical apertures throughout, the first aperture is specifically designed for lateral compensation and the second aperture for longitudinal compensation, optimizing each location's function to address specific dimensional variance issues.
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 approach reduces manufacturing stages and effectively compensates for dimensional variances, facilitating easier and more precise assembly of the choke coil by allowing adjustments through rotation and sliding of the coil components.
Implementation Method 1
forming the first aperture of the first terminal member and the second aperture of the second terminal member by bending the same elongated piece of electrically conducting material
Data Source
AI summary
A choke coil including a conductor element having a plurality of coil turns, a first terminal member adapted for electrically connecting the choke coil to a first circuit terminal of an electric circuit, and a second terminal member adapted for electrically connecting the choke coil to a second circuit terminal of the electric circuit. The first terminal member is adapted to compensate lateral dimensional variance between locations of the first circuit terminal and second circuit terminal, and the second terminal member is adapted to compensate longitudinal dimensional variance between locations of the first circuit terminal and second circuit terminal, wherein the lateral dimensional variance is perpendicular to a longitudinal direction of the choke coil extending between the first terminal member and the second terminal member, and the longitudinal dimensional variance is parallel to the longitudinal direction.