Multi-Layer Coil Bobbin Structure for Precise Round-Wire Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in uniformly winding round wires in multiple layers using an automatic winding machine, as the first layer often misaligns, leading to gaps and potential wire displacement, which slows down production and risks deformation of the wall portion, causing size changes and potential cracking.
Innovation Solution
The coil component and manufacturing method incorporate a bobbin with a winding portion featuring grooves for the first layer, a step between the flange and groove, and inclined guide and side surfaces on the wall portion, allowing for aligned winding and preventing wire displacement and wall deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two round wires are wound simultaneously in one turn using automatic winding wire machine, then productivity is improved, but alignment precision deteriorates causing round wires to be misplaced
Solution Approach 1:
The groove portion is provided in advance on the bobbin at the predetermined position where the first layer of round wires should be arranged. This preliminary structural preparation guides the automatic winding machine to place the round wires correctly from the first layer, ensuring alignment precision while maintaining high-speed automatic winding operation
Solution Approach 2:
The groove portion acts as an intermediary guide structure between the automatic winding machine and the round wires. It provides a physical pathway that ensures the round wires are placed at the correct position without requiring manual intervention, thus maintaining both automation and precision
2Quantity of substance
If round wires are wound in multiple layers, then coil capacity is improved, but alignment maintenance becomes difficult causing gaps and wire displacement
Solution Approach 1:
The step is provided in advance between the flange portion and the groove portion to prevent round wires from falling off to the lower layer. This preliminary protective structure maintains alignment precision throughout multi-layer winding by preventing wire displacement, allowing the coil capacity to be increased through additional layers without compromising alignment
Solution Approach 2:
The bobbin structure is segmented into distinct functional portions: the groove portion for guiding wire placement and the step for preventing wire displacement. This segmentation allows each portion to perform its specific function effectively, ensuring alignment maintenance across multiple layers
3Volume of moving object
If wall portion is made thin to reduce bobbin size, then compactness is improved, but structural strength deteriorates causing deformation and cracking
Solution Approach 1:
The wall portion is designed with different thicknesses at different locations: thinner at portions not subjected to high stress and thicker at portions where round wires contact and exert stress. This local quality optimization allows the bobbin to maintain compact overall size while ensuring sufficient structural strength where needed to prevent deformation and cracking
Data Source
AI summary
The coil component includes a plurality of coils 2 including round wires 22 arranged in alignment and wound in multiple layers and a bobbin 3 around which the coils 2 are wound. The bobbin 3 includes a winding portion 21 around which the coils are wound, a flange portion 22 provided at both ends of the winding portion 21, and the wall portion provided between the adjacent coils 2 and standing from the winding portion 21. The flange portion 22 includes an inclined guide 222 that spreads toward an opening 221. The winding portion 31 includes the groove portion 312 in which the round wire 22 as the first layer is fitted, and a step 313 provided between the flange portion 32 and the groove portion 312 and protrudes from the winding portion 31. The wall portion 33 includes an inclined side surface 332.