Flat-Wire Coil Housing Structure for Stable Core Alignment
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Solution Overview
Problem
Existing coil devices face challenges in achieving a compact size and stable positioning of the coil and core components, which affects their performance and mounting efficiency.
Innovation Solution
A coil device design featuring a flat wire coil, E-shaped cores, and a case with a housing portion that supports and stabilizes the coil and core, along with a coil supporting portion to prevent misalignment and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat coil and core are used without a housing structure, then the device can be simplified in structure, but the positioning stability and compactness of the coil and core are compromised
Solution Approach 1:
The case is divided into multiple functional portions: a housing portion that covers the coil, a core supporting portion that holds the core, and a coil supporting portion that supports the coil. This segmentation allows each portion to perform its specific function while collectively achieving stable positioning without excessive structural complexity
Solution Approach 2:
The case acts as an intermediary structure between the coil and core, providing a housing portion that covers and protects the coil, and supporting portions that stabilize both components. This intermediary structure enables compact integration while maintaining positioning stability
2Device complexity
If the coil and core are positioned without a supporting structure, then the device complexity is reduced, but misalignment and performance instability occur
Solution Approach 1:
The core supporting portion and coil supporting portion are designed in advance to provide predetermined support positions. The core supporting portion includes a supporting surface that preliminarily positions the core, while the coil supporting portion provides a supporting surface for the coil, ensuring proper alignment before final assembly
Solution Approach 2:
The case extends in multiple dimensions to provide comprehensive support: the housing portion covers the coil in one dimension, while the supporting portions extend in perpendicular directions to stabilize both the coil and core, achieving precise alignment through multi-dimensional positioning
3Volume of moving object
If a compact design is implemented without proper housing, then the device size is reduced, but cooling efficiency deteriorates
Solution Approach 1:
The case is segmented into distinct portions that serve different functions: the housing portion provides compact enclosure for the coil, while separate supporting portions ensure proper spacing and heat dissipation pathways, allowing compact design without compromising cooling efficiency
Solution Approach 2:
Different portions of the case have different structural qualities optimized for their specific functions: the housing portion is designed for compact coverage, while the supporting portions provide localized support and heat dissipation surfaces, achieving both compactness and effective cooling through localized structural optimization
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 design achieves a compact size, stable positioning, improved inductance characteristics, and enhanced cooling efficiency, facilitating high-density mounting and performance stability.
Implementation Method 1
a flat wire including a coil portion and a lead-out portion drawn out from the coil portion; a core disposed around the coil portion
Data Source
AI summary
A coil device includes a flat wire including a coil portion and a lead-out portion drawn out from the coil portion; a core disposed around the coil portion; and a case including a housing portion housing the coil portion along a housing direction perpendicular to a winding axis direction of the coil portion, a core supporting portion connected to one end of the housing portion in the housing direction and supporting the core, and a coil supporting portion supporting an outer circumferential surface of the coil portion. The housing portion covers at least a part of the outer circumferential surface of the coil portion.