Choke Coil Terminal Geometry for Circuit Terminal 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 and circuit terminals, leading to assembly challenges.
Innovation Solution
The method involves forming apertures in the terminal members by bending the elongated conducting material to compensate for lateral and longitudinal dimensional variances, eliminating the need for machining operations and allowing for easy adjustment of the choke coil's position to match circuit terminal locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining operations are used to form apertures in terminal members, then manufacturing precision of aperture positions can be achieved, but device complexity and number of manufacturing stages increase
Solution Approach 1:
The patent changes the method of aperture formation from machining (subtractive process) to bending (formative process). The apertures are created by bending the elongated conducting material during the coil forming process itself, rather than through separate machining operations. This parameter change in the manufacturing approach eliminates the need for additional machining stages while maintaining acceptable aperture positioning through the inherent control of the bending process.
Solution Approach 2:
The patent merges the aperture formation operation with the coil winding process. Both the coil turns and the terminal member apertures are formed in a single continuous process using the same elongated piece of conducting material. This consolidation eliminates separate machining stages and reduces overall manufacturing complexity while achieving both coil and aperture features simultaneously.
2Manufacturing precision
If multiple manual stages are used for manufacturing choke coil, then manufacturing precision can be controlled, but productivity decreases and manufacturing time increases
Solution Approach 1:
The patent incorporates aperture formation as a preliminary action during the coil winding process itself. The apertures are created in the terminal members before final assembly, by bending the conducting material during the initial forming stage. This preliminary action eliminates the need for subsequent separate aperture creation operations, thereby increasing productivity without sacrificing dimensional control.
Solution Approach 2:
The patent maintains continuous useful action by forming both the coil turns and terminal member apertures in a single uninterrupted process. The elongated conducting material is continuously formed into coils and bent into apertures without interruption or separate manual intervention stages. This continuous process improves productivity while maintaining precision through automated control of the forming and bending operations.
3Manufacturing precision
If identical rectangular apertures are machined to terminal members, then manufacturing consistency is achieved, but adaptability to dimensional variance in circuit terminals is reduced
Solution Approach 1:
The patent introduces dynamic adaptability by allowing the aperture positions and orientations to be adjusted during the bending process. Rather than fixing identical rectangular apertures through rigid machining, the bending process enables the apertures to be positioned and oriented to compensate for dimensional variances in circuit terminals. This dynamic approach maintains manufacturing consistency through controlled processes while achieving adaptability to varying terminal locations.
Solution Approach 2:
The patent changes the aperture formation from fixed machining parameters to flexible bending parameters. The bending process allows variation in aperture position, orientation, and shape to accommodate dimensional variances in circuit terminals. This parameter flexibility enables the same manufacturing process to produce adapted apertures for different terminal configurations while maintaining overall manufacturing consistency through process control.
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 the manufacturing stages, minimizes dimensional variance issues, and simplifies the assembly process by enabling straightforward compensation of terminal misalignments through aperture design, enhancing the manufacturing efficiency and reliability of choke coils.
Implementation Method 1
forming the first aperture by bending the elongated piece of electrically conducting material; forming the second aperture by bending the elongated piece of electrically conducting material
Data Source
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AI summary
A choke coil comprising a conductor element (2) having a plurality of coil turns, a first terminal member (41) adapted for electrically connecting the choke coil to a first circuit terminal (61) of an electric circuit, and a second terminal member (42) adapted for electrically connecting the choke coil to a second circuit terminal (62) of the electric circuit. The first terminal member (41) is adapted to compensate lateral dimensional variance between locations of the first circuit terminal (61) and second circuit terminal (62), and the second terminal member (42) is adapted to compensate longitudinal dimensional variance between locations of the first circuit terminal (61) and second circuit terminal (62), wherein the lateral dimensional variance is perpendicular to a longitudinal direction of the choke coil extending between the first terminal member (41) and the second terminal member (42), and the longitudinal dimensional variance is parallel to the longitudinal direction.