Tool-Free Choke Assembly With Latched Coil Body and Base Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of chokes with magnetic cores is labor-intensive and requires additional parts such as screws, pressure plates, and air gap plates, leading to high labor costs and material expenses.
Innovation Solution
A choke design featuring a coil body composed of two parts and a base plate, both equipped with latching elements for tool-free connection, allowing for the assembly of a magnetic core from stacked sheets without the need for fastening screws or air gap plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw joints and pressure plates are used to assemble the magnetic core sheets, then the assembly is secure and stable, but the labor effort and manufacturing complexity increase significantly
Solution Approach 1:
The patent removes screws, pressure plates, and air gap plates from the assembly process. The coil body itself is designed to directly hold the magnetic core sheets through its structural geometry, eliminating the need for separate fastening components and simplifying the assembly process while maintaining stability.
Solution Approach 2:
The functions of holding the magnetic core sheets and maintaining the air gap are merged into the coil body structure itself. The coil body's geometric design integrates both support and spacing functions, eliminating the need for separate air gap plates and pressure plates.
2Manufacturing precision
If additional parts such as air gap plates and fastening elements are used, then the air gap is precisely maintained and the assembly is secure, but the material costs and number of components increase
Solution Approach 1:
The patent eliminates air gap plates and fastening elements from the component list. The coil body's structural design directly provides the necessary air gap spacing and sheet retention without requiring additional parts.
Solution Approach 2:
The coil body serves multiple functions simultaneously: it holds the magnetic core sheets, maintains the air gap, and provides structural support. This multi-functionality reduces the total number of components needed while achieving the same precision and stability.
3Adaptability or versatility
If multiple separate components are used to construct the coil body and base plate, then the assembly is flexible and adaptable, but the assembly time and labor costs increase
Solution Approach 1:
The coil body is divided into at least two separable parts that can be assembled around the windings. This segmentation allows flexible assembly sequences while the latching elements enable quick connection without tools, balancing adaptability with assembly speed.
Solution Approach 2:
The latching elements are designed to automatically engage and lock the coil body parts together without requiring external tools or complex fastening operations. This self-latching mechanism maintains assembly flexibility while dramatically reducing assembly time and labor requirements.
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 enables quick and simple assembly of chokes without tools or additional parts, significantly reducing labor effort and material costs while maintaining the necessary air gap in the magnetic core.
Implementation Method 1
The at least two parts of the coil body and the base plate comprise first latching elements and second latching elements for tool-free connecting
Implementation Method 2
a magnetic core provided with an air gap, wherein a coil body consisting of at least two parts is provided for receiving the at least one winding
Data Source
AI summary
A choke includes at least one winding each having two connections, and a magnetic core having an air gap, wherein a coil body made up of at least two parts is provided for receiving the at least one winding, and a base plate that can be connected to the coil body is also provided. The at least two parts of the coil body and the base plate include first latching elements and second latching elements for tool-free connecting the at least two parts of the coil body and for tool-free connecting the base plate to the coil body, and the magnetic core is built up from sheets stacked one on top of the other, and the base plate is designed to receive the sheets of the magnetic core.