Electromagnetic Relay with Nested Metal-Plated Coils for Compact Assembly
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Solution Overview
Problem
Conventional electromagnetic devices with double-wound coils are bulky, making them difficult to compact and requiring time-consuming connection work, which lowers productivity.
Innovation Solution
A compact electromagnetic device with a secondary coil formed by metal plating on a cylindrical spool and a primary coil wound around it via an insulating material, eliminating the need for binding extended wires to terminals and simplifying connection work.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil is wound in two layers on the bobbin, then the electromagnetic device can function, but the device becomes bulky and cannot be made compact
Solution Approach 1:
The patent applies nesting by placing the primary coil inside the secondary coil, with the primary coil wound on the bobbin and the secondary coil wound around the primary coil. This nested configuration allows both coils to occupy the same spatial envelope, significantly reducing the overall device volume compared to conventional side-by-side or layered arrangements.
Solution Approach 2:
The patent transitions from a conventional two-layer winding on the same bobbin to a three-dimensional nested structure where coils are arranged concentrically along the radial dimension. This dimensional reorganization allows for more efficient space utilization and compact device geometry.
2Productivity
If extended wires of the coil are wound around external connection terminals, then electrical connection is achieved, but it takes time and effort for connection work and productivity is low
Solution Approach 1:
The patent merges the coil structure with the connection terminals by integrating the coil ends directly into the terminal assembly. The extended wires are pre-positioned and connected during the coil winding process itself, eliminating the need for separate connection operations and reducing assembly steps.
Solution Approach 2:
The patent performs connection preparation in advance during the coil winding process. The extended wires are positioned and preliminarily connected to terminals before the coil is fully assembled into the device, so that no additional connection work is required during final assembly, thereby improving productivity.
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 solution results in a more compact and productive electromagnetic device with reduced bulk and simplified assembly, as the secondary coil is formed by metal plating, allowing for efficient electromagnetic induction and energy savings.
Implementation Method 1
An induced current, generated by applying a voltage to any one of the primary coil and the secondary coil, is allowed to flow to the other coil different from the one coil
Implementation Method 2
a secondary coil formed in a spiral shape along an outer peripheral surface of the cylindrical body and formed with a closed circuit by metal plating
Data Source
AI summary
An electromagnetic device includes a spool having a cylindrical body with a through hole, a secondary coil formed in a spiral shape along an outer peripheral surface of the cylindrical body and formed with a closed circuit by metal plating, and a primary coil formed of a conductive wire wound around the secondary coil via an insulating material covering the secondary coil. An induced current, generated by applying a voltage to any one of the primary coil and the secondary coil, is allowed to flow to the other coil different from the one coil.