Coil Flange Groove Geometry for Flexible Wire Insertion
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Solution Overview
Problem
The existing winding-type coil components face challenges with low flexibility in inserting wires into grooves due to the parallel configuration of the groove sides, leading to restricted wire angles and increased positional variations within the groove.
Innovation Solution
The coil component design features grooves with a narrower distance between sides on the inner end surface and a wider distance on the outer end surface, along with smaller angles for the inner side and larger angles for the outer side relative to the axial direction, allowing for easier wire insertion and reduced positional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the groove sides extend in parallel with the axial direction of the winding core, then the groove structure is simple and easy to manufacture, but the flexibility in inserting the wire into the groove is low and the wire position varies significantly
Solution Approach 1:
The groove is designed with asymmetric side configurations: the first side extends in parallel with the axial direction while the second side is inclined relative to the axial direction. This asymmetric design allows the groove to accommodate wires inserted at different angles, improving insertion flexibility while maintaining manufacturing simplicity.
Solution Approach 2:
Different sides of the groove have different geometric properties tailored to specific functions: one side provides parallel guidance for wire insertion, while the other side offers inclined support to accommodate wire positioning variations, thereby optimizing both ease of manufacture and wire insertion flexibility locally.
2Ease of operation
If the groove width is increased to accommodate wire insertion, then the flexibility in inserting wire is improved, but the positional variation of the wire within the groove increases
Solution Approach 1:
The asymmetric groove configuration with one parallel side and one inclined side creates a positioning effect that reduces wire positional variation. The parallel side provides a reference surface that limits wire movement, while the inclined side accommodates insertion flexibility, thereby resolving the contradiction between insertion ease and position precision.
3Ease of manufacture
If the groove structure is made simple with parallel sides, then the manufacturing process is easy, but the wire may touch the rising surface and movement is hindered during insertion
Solution Approach 1:
The asymmetric groove design with one inclined side prevents wire contact issues during insertion. The inclined side creates sufficient clearance between the wire and groove surfaces, eliminating the hindrance caused by wire touching the rising surface, while the parallel side maintains manufacturing simplicity.
Data Source
AI summary
A groove for receiving an end portion of a wire is on a mounting surface of a flange. The groove extends in a direction in which an inner end surface and an outer end surface of the flange are linked with each other. The groove has a bottom surface sandwiched between first and second sides extending in the direction in which the inner end surface and the outer end surface are linked with each other. The first side is located closer to an extending position of the wire from a winding core than is the second side. The distance between the first side and the second side on the inner end surface is narrower and that on the outer end surface is wider. The angle of the first side with respect to an axial direction is smaller than that of the second side with respect to the axial direction.