Coil Device Stopper With Rotatable Base For Wire Positioning
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Solution Overview
Problem
Existing coil devices face challenges in securely accommodating and easily attaching conductive wires to their grooves, as they often protrude from the groove or require deformation, which can lead to interference with other components and increased resistance due to skin effect.
Innovation Solution
A coil device design featuring a stopper with a rotatable or deformable distal end portion that covers the conductive wire, allowing it to be securely positioned within the groove and easily attached, while maintaining a compact form factor by integrating the stopper within the coil base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard material wire is used, then the wire maintains its shape and structural integrity, but the wire may protrude from the groove and cannot be accommodated in a desired position
Solution Approach 1:
The wire is divided into multiple flexible strands (e.g., litz wire construction with multiple insulated copper strands) that can be independently bent and positioned. This segmentation allows the wire to maintain overall structural integrity while enabling precise positioning within the groove without protrusion.
Solution Approach 2:
The wire's physical parameters are changed by using materials with specific flexibility characteristics. The patent employs wires with controlled softness or flexibility parameters that allow them to conform to the groove shape while maintaining electrical integrity, preventing protrusion issues.
2Reliability
If adhesive resin is used to fix the wire, then the wire is securely fixed in the groove, but the attachment process becomes more complex and time-consuming
Solution Approach 1:
The groove is pre-designed with specific geometric features (such as undercut sections, flanges, or interlocking profiles) that automatically secure the wire in place during assembly. This preliminary structural preparation eliminates the need for additional adhesive materials and simplifies the manufacturing process while maintaining reliable fixation.
Solution Approach 2:
The wire and groove are designed to self-secure through their own geometric characteristics. The wire's flexibility and the groove's shape work together to create a self-locking mechanism that holds the wire firmly without requiring external adhesives or complex attachment procedures.
3Manufacturing precision
If the wire is deformed to fit the groove, then the wire can be accommodated in the groove, but the skin effect increases causing higher resistance
Solution Approach 1:
The wire is designed with dynamic flexibility that allows it to adapt to the groove's curvature through controlled deformation. The wire's flexible construction enables it to follow the groove's path while maintaining strand separation and orientation that minimizes skin effect, achieving both fit and low resistance.
Solution Approach 2:
The wire employs a flexible multi-strand construction with thin insulation layers that allows it to conform to the groove shape without excessive deformation of individual conductors. This flexible structure maintains good electrical contact and minimizes skin effect while achieving precise accommodation in the groove.
Data Source
AI summary
A coil device includes a conductive wire forming a coil, a coil base having a groove for accommodating the conductive wire, and a stopper being separate from the coil base and attached to the coil base to cover the conductive wire. The stopper includes a base portion attached to the coil base at a position adjacent the groove, and a distal end portion integrated with the base portion to cover the conductive wire. The base portion of the stopper is rotatable. Alternatively, the distal end portion of the stopper is deformable.