Annular Coil Device with Hook Projections for Insulation and Assembly
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Solution Overview
Problem
Conventional coil devices with annularly assembled magnetic cores face challenges in achieving high insulation between coils and magnetic cores, especially in high-voltage, high-current applications, and are prone to easy detachment during handling due to inadequate fixation.
Innovation Solution
The coil device features a pair of annularly assembled coil members with connecting portions that include hook-shaped projections and receivers, along with reinforcing projection plates, ensuring secure engagement and improved insulation by entirely enclosing the magnetic cores within resin cases, preventing easy separation before adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the magnetic core is not entirely covered with the insulation case, then the structure is simpler and easier to manufacture, but the insulation between the coil and the magnetic core is insufficient for high-voltage applications
Solution Approach 1:
The magnetic core is entirely enclosed within the insulation case, with the coil wound around the insulation case. This nested structure ensures that the magnetic core is completely isolated from the coil by the insulation case, providing sufficient insulation for high-voltage applications while maintaining ease of manufacture through the integrated design.
2Ease of manufacture
If the coil members are connected only by projections and recesses without adhesive, then the assembling is easier, but the coil members are easily detached by external force
Solution Approach 1:
The coil members are preliminarily connected by hook-shaped projections fitting into recesses, providing initial mechanical connection and positioning. This preliminary action enables easy assembling while the subsequent adhesive application reinforces the connection to prevent detachment by external forces.
Solution Approach 2:
The connection mechanism transitions from purely mechanical (projections and recesses) to a combination of mechanical and chemical bonding. The adhesive changes the bonding parameter from weak mechanical interlocking to strong chemical adhesion, preventing easy detachment while maintaining ease of assembling through the simple projection-recess geometry.
Data Source
AI summary
A coil device comprising a pair of coil members annularly assembled at two connecting end portions; each coil member comprising a magnetic core, a resin case substantially entirely surrounding the magnetic core, and a coil wound around the resin case; the resin case having connecting means and guide means in the connecting end portion of each coil member; and the connected coil members being adhered to each other in the connecting end portions.