Insulating Coil Bobbin with Segmented Flanges for Electrical Isolation
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Solution Overview
Problem
Conventional coil components lack effective electrical insulation between the coil winding and magnetic core, leading to potential contact and increased assembly complexity, which can result in short circuits and require additional parts or steps to improve insulation.
Innovation Solution
An electrically insulating coil bobbin with outwardly protruding insulating portions at both ends, designed to be inserted into the coil winding and rotated to interpose between the magnetic core and the winding, preventing contact without increasing the number of parts, utilizing a cylindrical shape with indentations and projections for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If another flange is provided at the other end of the insulating bobbin to improve electrical insulation, then the electrical insulation of the coil winding is improved, but the flange hinders the insertion of the insulating bobbin into the inside of the coil winding, making smooth insertion difficult
Solution Approach 1:
The insulating bobbin is divided into multiple insulating portions (first insulating portions at one end, second insulating portions at the other end) that are separated in the circumferential direction. This segmentation allows the insulating portions to provide electrical insulation without forming a continuous flange structure that would hinder insertion.
Solution Approach 2:
Insulating portions are provided only at specific locations (both ends of the cylindrical portion) rather than forming a continuous flange around the entire circumference. This local quality approach provides electrical insulation where needed while maintaining ease of insertion by leaving gaps in the circumferential direction.
2Reliability
If an insulating sheet is interposed between the other end of the coil bobbin and the magnetic core to enhance electrical insulation, then the electrical insulation is improved, but the number of parts increases, increasing assembling steps
Solution Approach 1:
The insulating portions are integrally formed with the cylindrical portion of the coil bobbin as a single piece, eliminating the need for separate insulating sheets or additional parts. This merging of functions reduces the number of parts and simplifies the assembly process while maintaining electrical insulation.
Solution Approach 2:
The coil bobbin itself provides the electrical insulation function through its integrally formed insulating portions, rather than requiring external insulating components. The insulating portions are built-in features of the bobbin structure, allowing it to serve its own insulation needs.
3Reliability
If two coil bobbins with flange at one end are used and inserted into respective openings at both ends of the coil winding, then electrical insulation is improved, but the number of parts increases, increasing assembling steps
Solution Approach 1:
A single coil bobbin is designed to provide electrical insulation at both ends through integrally formed first and second insulating portions, eliminating the need for two separate coil bobbins. This multi-functional design achieves the same insulation effect with fewer parts and simpler assembly.
Solution Approach 2:
The functions of two separate coil bobbins (each providing insulation at one end) are merged into a single coil bobbin that provides insulation at both ends through integrally formed insulating portions, reducing part count and assembly complexity.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A coil bobbin has a cylindrical portion around which a coil winding is wound. The coil winding is comprised of coil members of an end-defined ring shape, the coil members have indentations indented outwardly in part of their inner periphery, and circumferential positions of the indentations are coincident with those of the indentations. Claws and flanges protruding outwardly are integrally provided at both ends of the cylindrical portion, and the cylindrical portion is inserted into openings of the coil members so that the claws pass through the indentations. In a state in which the claws are located out of the coil member, the cylindrical portion is rotated whereby the coil winding is interposed between the claws and the flanges.