Magnetic Inductive Coil Module With Insulative Separator
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Solution Overview
Problem
Existing transformer manufacturing processes face challenges such as inadequate insulation between coil sets, complex and time-consuming assembly requiring precise alignment, and increased error rates due to manual terminal connections, which hinder efficient mass production and safety compliance.
Innovation Solution
A magnetic inductive coil module design featuring a first and second coil set separated by an insulative separator with positioning features, allowing for adjustable turns and improved connection reliability, and a coil base with conductive pins for external circuit connection, facilitating automatic assembly and enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If coils are coated with insulative paint for isolation, then insulation is provided, but safety specification requirements cannot be met and reliability deteriorates
Solution Approach 1:
An insulative separator is introduced as an intermediary component between the primary coil and secondary coil. This separator provides robust electrical isolation that meets safety specifications, unlike insulative paint coatings. The separator acts as a dedicated mediator structure that ensures reliable insulation while allowing the coils to maintain their functional design.
2Manufacturing precision
If each winding is assembled independently with precise alignment of assembling holes, then proper positioning is achieved, but assembling difficulty increases and productivity decreases
Solution Approach 1:
The first coil and second coil are merged into a single integrated coil assembly structure. This unified structure eliminates the need for separate alignment operations for multiple independent windings, as the coils are positioned relative to each other within the same assembly framework, significantly improving productivity.
Solution Approach 2:
The insulative separator is pre-positioned with positioning features that define the correct locations for coil assembly. This preliminary setup of reference positions allows subsequent coil attachments to be made quickly without requiring complex real-time alignment operations, thereby increasing assembling speed.
3Device complexity
If pins are fixed to an independent base in advance with one-to-one terminal connections, then connection structure is established, but manufacturing efficiency decreases and error rate increases
Solution Approach 1:
The connection terminals are merged directly with the coil structures themselves rather than being separate components attached to an independent base. This integration eliminates the need for separate pin attachment operations and reduces the number of connection steps, thereby improving manufacturing efficiency and reducing errors.
Solution Approach 2:
The independent insulative base with pre-fixed pins is extracted from the design, replacing it with a simplified structure where connection terminals are directly formed as part of the coil assembly. This removal of the separate base component reduces complexity and streamlines the manufacturing process.
4Adaptability or versatility
If more windings are connected to pins one-to-one, then all terminals are connected, but manufacturing time increases and yield rate decreases
Solution Approach 1:
The integrated coil assembly structure provides universal connection capability for multiple windings through a unified terminal structure. This multi-functional design allows all coil terminals to be connected simultaneously or in fewer steps rather than requiring separate one-to-one connections for each winding, reducing manufacturing time while maintaining the ability to connect any number of windings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances yield rate and reliability by simplifying assembly, improving insulation, and reducing errors, thus enabling more efficient and safer mass production of transformers.
Implementation Method 1
an insulative separator disposed between the first coil body and the second coil body
Implementation Method 2
a magnetic core inserted in the adopting hole
Data Source
AI summary
A coil module includes a first coil set; a second coil set, including a first coil body, a second coil body and an insulative separator disposed between the first coil body and the second coil body, the separator having an adopting hole, the first coil body having an open winding surrounding the adapting hole and fixed on a side of the separator, the second coil body having an open winding surrounding the adapting hole and fixed on another side of the separator; and a coil base sheathing the second coil set with exposing the adopting hole. The first coil set surrounds the adopting hole and is fixed on the coil base to form a coil module.