Coil Device Wire Fixing and Core Stability
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Solution Overview
Problem
The existing coil devices experience positional displacement of the inner core with respect to the outer core due to the design of the wirebound portion, which affects downsizing and performance consistency.
Innovation Solution
The coil device incorporates a pair of terminal portions with wirebound portions that include fixing and support elements, where the wire fixing portions bend to secure the wire ends in a specific direction, preventing displacement while allowing for rotation, and support portions prevent movement by touching the wire on the winding side, ensuring accurate fixation and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wirebound portion uses a pressing portion to press the end of the wire, then the wire fixation is improved, but positional displacement of the inner core relative to the outer core occurs
Solution Approach 1:
The wirebound portion is divided into functionally distinct elements: a pressing portion for securing the wire end and a support portion for maintaining positional accuracy. This segmentation allows each element to perform its specific function without interfering with the other, preventing positional displacement while ensuring reliable wire fixation.
Solution Approach 2:
Different regions of the wirebound portion are given different functional properties. The pressing portion provides localized pressure for wire fixation, while the support portion provides localized support for positional stability. This local differentiation of quality allows simultaneous achievement of wire security and positional precision.
2Strength
If the wire fixing portion bends to fix the wire end, then the wire is securely fixed, but a force is generated that may rotate or displace the inner core
Solution Approach 1:
The support portion acts as a counterbalancing element that offsets the rotational force generated by the bending wire fixing portion. By positioning the support portion to touch the wire on the winding side, it creates a counteracting moment that prevents the inner core from rotating or displacing, while the wire remains securely fixed.
3Ease of manufacture
If the wirebound portion design is simplified for ease of manufacture, then manufacturing efficiency is improved, but positional displacement control deteriorates
Solution Approach 1:
The wirebound portion integrates multiple functions into a single component: wire holding, wire pressing for fixation, and positional support. This merging eliminates the need for separate assembly steps for multiple components, simplifying manufacturing while maintaining precise positional control through the integrated support portion.
Data Source
AI summary
A coil device includes an inner core having a winding core and a pair of flanges, a wire, an outer core arranged outside the inner core, a first terminal with a first wirebound having a first wirebound bottom arranged axially on a core end surface of the outer core and connected to a first end of the wire, and a second terminal with a second wirebound having a second wirebound bottom arranged on the core end surface and connected to a second end of the wire. The first wirebound has a first wire fixing portion bending from the first wirebound bottom toward a first rotating direction and fixing the first end. The second wirebound has a second wire fixing portion bending from the second wirebound bottom toward the same rotating direction as the first rotating direction and fixing the second end.