Flat Coil Carrier Groove Spiral Undercut Axial Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production and assembly of flat coils for inductive charging devices, such as in motor vehicles, are complicated due to the need for precise and predetermined arrangement of coil wires, which often requires on-site assembly to prevent axial and radial displacement, making preassembly and large-scale production challenging.
Innovation Solution
A flat coil carrier with a groove spiral featuring undercuts that axially fix the coil wire, allowing for easier and more precise positioning, enabling preassembly and simplifying production by preventing axial movement and ensuring precise electromagnetic field generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil wire is received in a groove spiral without undercuts, then the coil wire can be easily inserted, but the coil wire cannot be axially fixed and may displace unintentionally
Solution Approach 1:
The groove spiral transitions from a simple planar groove to a three-dimensional structure with undercuts that extend radially inward. This dimensional change creates axial fixation zones that prevent coil wire displacement while maintaining ease of insertion through the open groove opening.
Solution Approach 2:
The groove spiral is segmented into different functional zones: insertion zones with open groove openings that allow easy coil wire insertion, and fixation zones with undercuts that axially secure the coil wire. This segmentation allows each zone to perform its specific function optimally.
2Reliability
If the coil wire is fixed by frontal attachment of axially adjacent component, then axial and radial displacement is prevented, but production and assembly becomes more complicated
Solution Approach 1:
The groove spiral structure provides self-fixation through its undercut geometry. When the coil wire is inserted, the undercut zones automatically engage and axially secure the wire without requiring additional fixation components or complex assembly operations.
Solution Approach 2:
The reception function and fixation function are merged into a single groove spiral structure. The same groove that receives the coil wire also contains the undercuts that axially fix it, eliminating the need for separate fixation mechanisms.
3Ease of manufacture
If the groove spiral is open axially without undercuts, then the coil wire can be inserted easily, but preassembly is not possible and production is more complicated
Solution Approach 1:
The undercut structure enables preliminary action by allowing the coil wire to be pre-positioned and axially fixed in the groove spiral during preassembly operations. The open groove openings facilitate insertion while the undercuts provide immediate axial securing, enabling precise predetermined arrangement before final application.
Data Source
AI summary
A flat coil carrier may include a carrier body. The carrier body may include, on an axial front side, a groove spiral configured to receive a coil wire. The groove spiral may have an axially open groove opening and may include a plurality of radially consecutive groove sections. The plurality of radially consecutive groove sections may each have an axially open groove section opening of a plurality of groove section openings. The plurality of radially consecutive groove sections may each be separated from one another by a common separating wall section of a plurality of separating wall sections of the carrier body. At least one of the plurality of separating wall sections may protrude from the carrier body and may have at least one undercut section including a radially protruding protrusion such that an undercut for the coil wire is formed in the at least one undercut section.