Coil Device Bobbin Retainer for Flat Coil Positioning
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Solution Overview
Problem
Existing coil devices with flat coils face manufacturing complexities and positioning accuracy issues due to the need for multiple bobbin parts and precise tolerance considerations.
Innovation Solution
A coil device design featuring a bobbin with an accommodation groove for lateral insertion of the flat coil and a retainer member to prevent misalignment, eliminating the need for multiple bobbin parts and enhancing positioning accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bobbin is made up of a plurality of parts to accommodate the flat coil, then the flat coil can be covered from above and below, but the manufacturing operation becomes complicated and positioning accuracy is difficult to ensure
Solution Approach 1:
The bobbin is divided into an upper bobbin and a lower bobbin that are coupled together. The upper bobbin includes an upper accommodating portion with an insertion groove for receiving the flat coil, while the lower bobbin includes a lower accommodating portion. This segmentation allows the flat coil to be securely positioned between the two bobbins while simplifying the overall structure compared to a single-piece design with integrated positioning features.
Solution Approach 2:
A positioning protrusion is provided on the upper bobbin that fits into a positioning groove on the lower bobbin. This positioning structure acts as an intermediary mechanism that ensures accurate alignment and positioning of the flat coil between the upper and lower bobbins, thereby guaranteeing positioning accuracy while maintaining structural simplicity.
2Ease of manufacture
If the bobbin is made up of a plurality of parts, then the flat coil can be accommodated, but tolerance of the parts affects positioning accuracy
Solution Approach 1:
The positioning protrusion and positioning groove are pre-formed on the upper and lower bobbins respectively. These preliminary positioning structures ensure that when the upper and lower bobbins are assembled, the flat coil is automatically positioned with high accuracy without requiring tight tolerances on all mating surfaces. The positioning features are designed in advance to compensate for normal manufacturing tolerances.
3Manufacturing precision
If the retainer member is integrated with the bobbin, then positioning is improved, but the insertion passage for the flat coil may be blocked
Solution Approach 1:
The retainer member is separated from the bobbin structure and designed as an independent component. This segmentation allows the retainer member to be installed after the flat coil is positioned in the insertion groove, ensuring that the insertion passage remains unblocked during the assembly process. The separated retainer member can be easily attached to the bobbin to provide positioning without interfering with coil insertion.
Data Source
AI summary
A coil device 1 includes cores 30b and 30c; flat coils 93a to 93d each having a flat wire; a bobbin 20 having a through-hole 210 in which legs 33b and 33c of the cores 30b and 30c are disposed and accommodation grooves 220a to 220d into which the flat coils 93a to 93d are laterally inserted; and a retainer member 80 inserted into the through-hole 210 and disposed at inner circumferential sides of the flat coils 93a to 93d.