Flat-Conductor Coil Forming for Dense, Heat-Dissipating Windings
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Solution Overview
Problem
Existing coil manufacturing methods lack sufficient examination for mass-production of high-quality coils with enhanced space factor and heat dissipation performance.
Innovation Solution
A method involving the preparation of strip-shaped flat conductors, welding, annealing, and molding steps to form a helical structure body, followed by insulation and shaping to create a coil with improved space factor and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flat conductors are continuously joined through welding to form a helical structure, then the space factor and heat dissipation performance are enhanced, but the manufacturing productivity and mass-production capability are insufficient
Solution Approach 1:
The manufacturing process is divided into distinct segments: preparing multiple U-shaped flat conductors, welding end faces to form turn regions, and continuously joining regions to form the helical structure. This segmentation enables standardized mass-production while maintaining quality
Solution Approach 2:
Multiple U-shaped flat conductors are prepared in advance before the welding and assembly process. This preliminary preparation of components enables efficient mass-production by having ready-to-use elements for continuous assembly into helical structures
2Volume of moving object
If flat conductors are welded to form a helical structure, then the space factor in the core is enhanced, but the welded portions may experience property deterioration
Solution Approach 1:
Traditional welding methods that may damage material properties are replaced with cold pressure welding, a mechanical joining process that connects flat conductors without thermal input, thereby preventing property deterioration in welded portions while maintaining structural integrity for enhanced space factor
Solution Approach 2:
The joining process parameters are changed from thermal welding to cold pressure welding, altering the fundamental mechanism of connection to preserve material properties in welded portions while achieving the necessary structural formation for enhanced space factor
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
Enables mass-production of coils with enhanced space factor and heat dissipation performance, ensuring high-quality output.
Implementation Method 1
welding the end faces of the flat conductors to each other through cold pressure welding to form a region for one turn of the coil
Implementation Method 2
an annealing step of the helical structure body
Data Source
AI summary
Provided is a method for manufacturing a coil enabling mass-production of good-quality coils that have an enhanced space factor in a core and enhanced heat dissipation performance and that are free from deterioration in properties due to cutting and welding. A method for manufacturing a coil includes: a step of preparing a plurality of strip-shaped flat conductors which can constitute a helical structure body when the flat conductors are continuously joined; a welding step of forming the helical structure body by butting and pressing one end face of one of the flat conductors in a strip longitudinal direction and one end face of another one of the flat conductors in the strip longitudinal direction; an annealing step of the helical structure body; an insulation step of the helical structure body; and a molding step of forming the helical structure body into a desired shape.