Coil Filter Core With Asymmetric Protrusions
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Solution Overview
Problem
Conventional coil filters often waste space on the core member due to their predetermined size or shape, which restricts the efficient winding and engagement of coil windings, leading to inefficient use of the core member's space.
Innovation Solution
A coil filter design featuring a core member with strategically positioned protrusions and projections that allow windings to be wound and secured without wasting space, with different widths and depths of protrusions and projections enabling compact and efficient engagement of multiple windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a core member with predetermined size or shape is used, then the structure is simple and easy to manufacture, but space on the core member is wasted and windings cannot be efficiently engaged
Solution Approach 1:
The core member is segmented into multiple functional regions through protrusions and projections. The front protrusion, rear protrusion, and middle protrusion divide the core into distinct winding zones, allowing efficient engagement of multiple windings without wasting space. Each protrusion serves as a dedicated engagement point for coil terminals.
Solution Approach 2:
The core member extends in multiple dimensions with protrusions and projections created in different directions (front, rear, middle, upward). This multi-dimensional structure maximizes space utilization by engaging windings at various positions and orientations, transforming a simple linear core into a three-dimensional winding engagement system.
2Productivity
If protrusions with different widths are used, then space utilization is improved, but device complexity increases
Solution Approach 1:
Different protrusions have different widths tailored to their specific functions. The front protrusion has width W, the rear protrusion has width T, and the middle protrusion has width t, with W > T > t. This local differentiation optimizes space utilization for each winding zone while maintaining overall structural coherence and manufacturability.
Solution Approach 2:
The core member features asymmetric protrusions with varying widths and positions. The front protrusion is wider than the rear protrusion, which is wider than the middle protrusion. This asymmetric design allows optimal engagement of multiple windings with different dimensions, maximizing space utilization without requiring a completely complex custom structure.
Data Source
AI summary
A coil filter includes a core member having two end members extended from two end portions, the left end member includes a front protrusion, a rear protrusion, and a middle protrusion extended upwardly beyond the core member, the front protrusion includes a width (W) greater than that of the rear protrusion and the middle protrusion, the second end member includes a rear projection, a front projection, and a middle projection extended upwardly beyond the core member, the rear projection includes a width (T) greater than the width (t) of the front projection and the middle projection, and a coil member wound onto the core member and disposed between the end members without wasting the spaces of the core member.