Flat Wire Coil Insulation via Core Protrusions
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Solution Overview
Problem
The production cost of reactors is increased due to the need for additional insulating materials and complex assembly processes to achieve insulation between the core and the ends of coils wound with flat type wire materials, especially when these ends need to be connected to other circuits.
Innovation Solution
A coil is formed by winding flat type wire materials edgewise, with the start-of-winding and finish-of-winding edges projecting from the coil's circumference, allowing for insulation without additional insulating members, thereby reducing the need for extra parts and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flat type wire material is wound edgewise to achieve high lamination factor, then winding efficiency is improved, but insulation between coil ends and core becomes difficult without additional insulating materials
Solution Approach 1:
The patent merges the insulation function into the core structure itself by forming protrusions that extend into the coil winding. This integrates the insulation function with the core, eliminating the need for separate insulating materials and simplifying the overall structure while maintaining high winding efficiency with flat type wire material.
Solution Approach 2:
The protrusions formed on the core serve as intermediary structures between the core and the coil winding. These protrusions create physical separation and insulation between the conductive core and the coil ends, acting as a mediator that provides insulation without requiring additional insulating materials.
2Reliability
If additional insulating materials are used to ensure insulation between coil ends and core, then insulation reliability is improved, but production cost and assembly complexity increase
Solution Approach 1:
The insulation function is merged into the core structure through protrusions, eliminating the need for separate insulating materials. This reduces production costs by removing additional material costs and assembly steps while maintaining insulation reliability through the integrated structural design.
Solution Approach 2:
The core structure provides its own insulation function through the protrusions that extend into the coil winding. This self-service approach eliminates the need for external insulating materials and simplifies manufacturing while ensuring reliable insulation between the core and coil ends.
3Ease of operation
If films covering coil ends are removed for connection to other circuits, then electrical connectivity is improved, but insulation from core may be compromised
Solution Approach 1:
The protrusions act as permanent intermediary structures that maintain insulation between the core and coil ends even after the films are removed for electrical connections. This allows the coil ends to be connected to other circuits while the protrusions continue to provide the insulation barrier from the core.
Solution Approach 2:
The protrusions are formed on the core before the coil winding is completed, establishing the insulation structure in advance. This preliminary action ensures that insulation is already in place before the coil ends need to be connected to other circuits, maintaining both connectivity and insulation reliability.
Data Source
AI summary
A coil formed by winding one flat type wire material rectangularly edgewise thereby stacking the rectangularly edgewise wound flat type wire in rectangular tube shape, wherein not only one edge of the coil including the flat type wire including an end portion of start-of-winding thereof but also another edge of the coil including the flat type wire including an end portion of finish-of-winding thereof are formed to be projecting from an outer circumference of the coil.