Coil Assembly Support Pin for Vibration Shielding
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Solution Overview
Problem
Existing coil assemblies in electronically controlled brake systems face challenges in maintaining stable contact with printed circuit boards, leading to electromagnetic wave shielding issues and vulnerability to vibrations, which increases costs and manufacturing complexity, and can result in solenoid valve operation failures.
Innovation Solution
A coil assembly design featuring a cylindrical bobbin with a through hole, a coil case, and a support pin that is bent to absorb vibrations and electrically couples the coil case to the printed circuit board, effectively shielding electromagnetic waves and preventing damage from external shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If separate members are provided for making contact structure between printed circuit board and hydraulic control unit to shield electromagnetic waves, then electromagnetic wave shielding is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coil case is merged with the contact structure by forming an integrated support pin directly from the coil case material. This combines the electromagnetic shielding function (coil case) with the electrical contact function (support pin) into a single unified component, eliminating the need for separate shielding members and reducing overall structural complexity
Solution Approach 2:
The coil case serves multiple functions simultaneously: it provides electromagnetic shielding, structural support, and electrical contact through the integrated support pin. This multi-functional design eliminates the need for separate dedicated shielding components while maintaining all required functions
2Reliability
If lead wires are coupled to printed circuit board using soldering to make electrical contacts, then electrical connection is achieved, but reliability deteriorates due to crack development from vibration and heavy coil weight
Solution Approach 1:
The support pin acts as an intermediary component between the coil assembly and the printed circuit board. Instead of directly soldering lead wires to the PCB, the support pin provides a mechanical and electrical interface that absorbs vibration stresses, protecting the solder joints from crack development while maintaining reliable electrical connection
Solution Approach 2:
The support pin structure is designed to beforehand cushion and absorb vibration stresses before they can reach the solder joints. By positioning the support pin to intercept and dampen vibrations at the source (coil assembly level), the design prevents vibration damage to the electrical connections before cracks can develop
3Stability of the object's composition
If coil assembly uses heavier weight to ensure structural stability, then structural stability is improved, but reliability deteriorates due to increased vibration damage and soldering cracks
Solution Approach 1:
The design replaces the traditional mechanical soldering connection system with a support pin-based mechanical and electrical interface. The support pin provides both structural stability and electrical connection without relying on vulnerable solder joints, eliminating the trade-off between coil weight and connection reliability by using a different mechanical connection mechanism
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 design ensures stable operation of the solenoid valve by maintaining a secure electrical connection, reducing manufacturing costs, and effectively shielding electromagnetic waves, thereby enhancing the reliability of the brake system.
Implementation Method 1
the solenoid valve includes a coil assembly which forms an electromagnetic field when a coil is wound and electric power is applied
Implementation Method 2
a support pin installed at the printed circuit board and provided on the coil case to electrically couple the coil case and the printed circuit board
Data Source
AI summary
Disclosed herein is a coil assembly. According to an aspect of the present invention, in a coil assembly which is coupled to a printed circuit board and applies electric power to a solenoid valve installed in a hydraulic control block, a coil assembly is provided including a bobbin having a through hole in the center so that a portion of the solenoid valve is inserted therein and having a coil wound around the outer circumference thereof, a coil case installed to wrap an outer side of the bobbin, a lead wire electrically coupling the printed circuit board and the coil assembly, a support pin integrally provided with the coil case to electrically couple the coil case and the printed circuit board.