Graphene Coil Winding Space Optimization
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Solution Overview
Problem
Existing electromagnetically excitable coils face inefficiencies in utilizing winding space, particularly when the conductor strip width exceeds the available winding space, leading to suboptimal fill factors and increased material usage.
Innovation Solution
The coil is designed with a conductor strip that is wound in a trapezoidal shape by folding or angling its cross-section, allowing it to fit optimally within varying winding spaces, and utilizing insulating elements with specific contours to enhance layer structure and fill factor, while also allowing for different conductor cross-sections and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conductor strip with fixed width is used for winding, then the manufacturing process is simple, but the winding space utilization is suboptimal when the conductor width exceeds the available winding space
Solution Approach 1:
The conductor strip transitions from a rigid fixed-width configuration to a dynamic adaptable configuration through folding and angling. The strip can be folded at specific points and angled at controlled angles to match varying winding space widths, allowing the same conductor strip to adapt to different winding spaces while maintaining manufacturing simplicity.
Solution Approach 2:
The conductor strip utilizes the third dimension by folding back on itself and angling in vertical/diagonal orientations. Instead of simply laying flat in one layer, the strip creates multi-level structures with folds and angles that optimize space utilization in the available winding volume.
2Volume of moving object
If the conductor strip width is reduced to fit narrower winding spaces, then the winding space utilization improves, but the conductor cross-section and electrical performance are compromised
Solution Approach 1:
The conductor strip is folded back on itself, creating a nested configuration where multiple layers of the same conductor strip occupy the same winding space. This nesting allows the full conductor cross-section to be utilized while fitting within narrower winding spaces, as the folded layers stack within the available volume.
3Ease of manufacture
If conventional wire windings with individual overhangs are used, then the winding process is straightforward, but the coil geometry precision and fill factor are reduced
Solution Approach 1:
The conductor strip is divided into functional segments: straight sections for winding, folded sections for geometry definition, and angled sections for space optimization. These segmented portions work together to achieve precise trapezoidal geometry while maintaining a straightforward winding process using standard equipment.
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
This design optimizes the use of winding space, increases fill factor, and allows for adaptable characteristic curves, enabling efficient use of conductor strips across different widths and geometries, reducing material waste and improving electrical performance.
Implementation Method 1
an electromagnetically excitable coil (1) which is formed by winding at least one electrical conductor (2), wherein the electrical conductor (2) comprises graphene and/or carbon nanotubes
Implementation Method 2
electromagnetically excitable coil
Data Source
Figure 1
Figure 2
AI summary
Electromagnetically excitable coils which are each formed by winding an electrical conductor which comprises graphene and/or carbon nanotubes are already known. According to the invention, the coil can be produced with a conductor strip in such a way that a winding space which is available to the coil is utilized in an optimum manner. According to the invention, provision is made for the at least one electrical conductor (2) to be designed as a conductor strip and to be wound in such a way that its conductor cross section is folded and/or angled over a certain length.