Additive Conductive Coil Staggered Pillar Density
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Solution Overview
Problem
Existing additive manufacturing methods for fabricating conductive coils face limitations in coil density and magnetic field shaping due to fixed geometry and pillar placement, which restricts the number of turns per unit length and uniformity of magnetic field characteristics.
Innovation Solution
The method involves printing conductive coils as partially complete rounds with staggered, vertically or near-vertically positioned pillars of varying heights, allowing for controlled density and interconnection of concentric coil columns to optimize coil density and magnetic field properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed geometry and pillar placement are used in additive manufacturing of conductive coils, then the manufacturing process is simple, but the coil density and number of turns per unit length are limited
Solution Approach 1:
The coil structure is segmented into multiple partial rounds rather than continuous loops, allowing independent optimization of each segment's position and orientation. This segmentation enables higher packing density while maintaining manufacturing simplicity through standardized segment fabrication.
Solution Approach 2:
Pillars are positioned at staggered angular offsets between successive layers, transitioning from a single-plane arrangement to a three-dimensional distributed configuration. This dimensional change increases the number of turns per unit length while managing structural complexity through systematic angular distribution.
2Manufacturing precision
If uniform pillar placement is used, then the manufacturing process is straightforward, but the magnetic field uniformity and characteristics cannot be optimized
Solution Approach 1:
Pillars are positioned with specific angular offsets that vary by layer, creating locally optimized magnetic field characteristics in different regions of the coil. This non-uniform local arrangement improves overall magnetic field uniformity while maintaining a systematic positioning strategy based on angular progression.
Solution Approach 2:
The pillar placement introduces controlled asymmetry through angular offsets between layers, breaking the symmetry of uniform cylindrical coils. This asymmetric positioning strategy optimizes magnetic field distribution and reduces harmonics while following a predictable angular progression pattern.
3Productivity
If complete rounds are printed in each layer, then the coil structure is simple and robust, but the coil density is reduced due to required spacing between turns
Solution Approach 1:
Complete circular rounds are segmented into partial arcs that terminate before forming closed loops. This segmentation allows closer spacing between adjacent turns by eliminating the need for gapless circular continuity, thereby increasing coil density while maintaining structural integrity through pillar connections.
Solution Approach 2:
Instead of printing complete 360-degree rounds, only partial arcs (less than full circles) are deposited in each layer. This partial action approach increases the number of layers that can be packed into a given length, enhancing coil density while the pillar connections provide the necessary structural completion.
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
This approach enables the fabrication of coils with adjustable density and magnetic field characteristics, allowing for increased turns per unit length and tailored electromagnetic properties, enhancing the versatility and performance of conductive coils in various applications.
Implementation Method 1
additive manufacturing build three dimensional articles from digital files describing those articles by successively adding material layer-by-layer
Implementation Method 2
a metal source such as a thin wire or foil is heated, for example by a laser beam, to create metal droplets
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A conductive coil fabricated by an additive manufacturing process. The coil is printed as a plurality of partially complete rounds, each printed as at least a portion of a respective layer of material. Pillars interconnecting successive ones of the partially complete rounds in different ones of the respective layers of material are also printed and may be staggered across a circumference of the partially complete rounds. Scaffolding elements such as a supporting material matrix and/or a core internal to the partially complete rounds of the coil may be printed as part of each respective layer of material concurrently with printing the plurality of partially complete rounds.