Coil Former Flange Layout for Larger Winding Windows
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Solution Overview
Problem
Existing coil formers for inductive components have a smaller winding window due to the presence of flanges, which restricts heat transfer and can damage e-cores during handling.
Innovation Solution
The coil former design modifies the flanges to avoid no-flange areas at interface points with cores, increasing the winding window and improving heat transfer, while additional flanges provide protection to the cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flanges are added to constrain coil wires, then wire constraint is improved, but winding window area is reduced
Solution Approach 1:
The patent removes flanges from specific areas where they would interfere with core placement, extracting only the necessary flange portions from the coil former structure. This allows the winding window area to be maximized while retaining flanges in areas where they are still needed for wire constraint.
Solution Approach 2:
The patent applies flanges selectively in different locations of the coil former - present in areas where wire constraint is needed and absent in areas where core access is required. This local differentiation resolves the contradiction by making the structure have different properties in different spatial locations.
2Ease of operation
If flanges are positioned between coil wires and e-cores, then wire constraint is improved, but heat transfer is restricted
Solution Approach 1:
The patent removes flanges from the interface areas between coil wires and e-cores, eliminating the thermal barrier that flanges create. This extraction of flange material from critical heat transfer zones allows direct thermal contact between wires and cores while maintaining wire constraint through flanges in non-critical areas.
3Ease of operation
If flanges are positioned at passageway ends, then wire constraint is improved, but core protection is reduced
Solution Approach 1:
The patent introduces additional flanges as intermediary protective elements positioned adjacent to e-cores but not between the cores and coil wires. These additional flanges serve as mediators that protect vulnerable core edges from damage during handling and assembly, while the main flange structure remains optimized for wire constraint and heat transfer.
Data Source
AI summary
Coil formers having flanges selectedly removed at interface areas with a core can provide advantages of increase a winding window and better heat transfer. The coil former can also have added flanged adjacent to the core to provide added protection to the core. Examples of e-cores and PQ cores are shown.