Coil Assembly Fork-Shaped Support Elements
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Solution Overview
Problem
Existing coil arrangements face challenges in achieving stable support and alignment without additional stiffening measures, leading to instability and increased electrical losses due to the presence of winding stars, which also result in noise and reduced electromagnetic coupling when coils are stacked.
Innovation Solution
A star-free and core-free coil design featuring fork-shaped support elements that securely support the coils radially, allowing for precise centering and alignment, eliminating the need for winding stars and reducing eddy current losses, while enabling closer coil stacking for improved electromagnetic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If winding stars are used to support the coil, then the coil structure is stabilized, but electrical losses increase due to eddy currents and mechanical resonances occur causing noise
Solution Approach 1:
The patent removes the winding star from the coil structure entirely, extracting the problematic component that causes eddy current losses and mechanical resonances. The coil is designed to function without this traditional support element, eliminating the source of electrical losses and noise while maintaining structural integrity through alternative means.
Solution Approach 2:
The support elements serve multiple functions: they provide mechanical support for the coil windings, maintain the geometric shape, enable precise alignment, and eliminate the need for separate winding stars. This multi-functional design replaces the single-function winding star with a more versatile component that avoids electrical losses.
2Stability of the object's composition
If winding stars are used to support the coil, then the coil structure is stabilized, but noise emissions increase due to mechanical resonances
Solution Approach 1:
The winding star is completely removed from the design, eliminating the component that generates mechanical resonances and associated noise. The coil structure is redesigned to achieve stability without this resonant-prone element.
Solution Approach 2:
The patent converts the structural support function previously performed by the noisy winding star into a different configuration that achieves the same mechanical stability without generating harmful vibrations or noise, effectively turning a harmful component into a beneficial design choice.
3Quantity of substance
If coils are stacked one above the other, then space is utilized efficiently, but electromagnetic coupling is reduced due to increased distance
Solution Approach 1:
The patent optimizes the vertical spacing between stacked coils by removing the winding star, allowing coils to be positioned closer together in the axial dimension. This dimensional optimization maintains efficient electromagnetic coupling while achieving high space utilization through vertical stacking.
Data Source
Figure 1
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AI summary
The invention relates to a coil assembly (1) comprising a first coil (2) having at least one winding layer (4) and a support assembly (23). The support assembly (23) comprises at least three first support elements (16), which are arranged at a first end region (17) of the first coil (2). The first support elements (16) are fork-shaped and each comprise a first support element base (26) as well as at least one first inner support element prong (27) and at least one first outer support element prong (28), the support element prongs (27, 28) each protruding from the first support element base (26) and being arranged at a distance from one another so as to form a first receiving slot (29). The at least one first winding layer (4) is received in the first receiving slot (28) and is supported on the first support element bases (26).