Magnetic Component Winding Fixing via Coil Pressing
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Solution Overview
Problem
Current magnetic components without bobbins face challenges in fixing the winding structure, leading to inefficiencies and potential quality issues such as collapse and looseness, which affect the electrical performance and power density.
Innovation Solution
A magnetic component design featuring a magnetic core with a winding comprising a first and second coil, where a cladding member covers the external surface of the first coil and a positioning member extends from it, pressed by the second coil to enhance fixing strength and reduce quality issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the bobbin is omitted to increase power density, then the volume of winding space is reduced, but the fixing strength of the winding deteriorates
Solution Approach 1:
The winding structure is segmented into multiple coils (first coil, second coil, third coil) with distinct functional zones. The first coil serves as the winding body, the second coil acts as a pressing coil for fixation, and the third coil provides additional support. This segmentation allows each segment to perform its specific function optimally while maintaining overall structural integrity without requiring a bobbin.
Solution Approach 2:
An insulating member is introduced as an intermediary element between the first coil and the magnetic core. This insulating member not only provides electrical insulation but also serves as a positioning structure that helps maintain the spatial relationship between coils and the core, thereby contributing to the fixing strength of the winding structure in the absence of a bobbin.
2Stability of the object's composition
If tapes are used to fix the winding on four sides, then the winding structure is constrained, but the operation complexity increases and efficiency decreases
Solution Approach 1:
The second coil serves a dual function: it is both part of the electrical winding structure and acts as a self-fixing element that presses and secures the first coil to the magnetic core. This self-service mechanism eliminates the need for separate fixing tapes or additional fixation operations, thereby reducing operational complexity while maintaining winding structure stability.
Solution Approach 2:
The second coil performs multiple functions simultaneously: it provides electrical winding functionality, acts as a pressing mechanism for fixation, and contributes to the overall structural stability. This multi-functionality reduces the need for separate fixing components and simplifies the overall device structure.
3Stability of the object's composition
If tapes are used to fix the winding, then the winding position is constrained, but the winding formation may collapse or become loose
Solution Approach 1:
The mechanical fixing system using tapes is replaced with an integrated coil pressing mechanism. The second coil, through its winding tension and positioning, mechanically presses the first coil against the magnetic core, providing more reliable and uniform constraint compared to tape fixation. This substitution eliminates the risks of tape loosening or winding collapse.
Solution Approach 2:
The second coil is pre-positioned and wound in such a way that it automatically exerts pressing force on the first coil during the winding process. This preliminary action ensures that the winding structure is constrained and stabilized during formation, preventing collapse or looseness before the component is complete.
Data Source
AI summary
The present application discloses a magnetic component, comprising a magnetic core comprising at least one core column; a winding winded on the core column and comprising a first coil and a second coil adjacent to the first coil; a cladding member covered on at least a portion of an external surface of the first coil; and a positioning member extending from the cladding member and the first coil, wherein the second coil is pressed on the positioning member.