Offset Coil Core for Slim Switching Devices
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Solution Overview
Problem
Existing switching devices, such as electromagnetic relays, face size constraints due to the width determined by the core and coil, making it challenging to create smaller and slimmer devices.
Innovation Solution
A core for a coil with an armature abutment section, armature bearing section, and a coil section that extend along separate planes offset from each other, allowing for a slimmer design by reducing the protruding width of the coil and enabling a more compact assembly without additional bobbins, using a magnetic core with offset planes and a thin elongated shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil and core are arranged in a conventional aligned manner, then the assembly is simple to manufacture, but the width of the switching device increases
Solution Approach 1:
The patent applies dimensionality change by offsetting the coil section from the armature bearing section along the longitudinal axis, creating a stepped configuration. This rearranges components along the length dimension rather than arranging them side-by-side in width, thereby reducing the overall width of the switching device while maintaining functional integrity.
Solution Approach 2:
The core is segmented into distinct sections: an armature bearing section and a coil section that are offset from each other. This segmentation allows each section to be optimized independently and enables the reduced width configuration by separating the coil mounting function from the armature mounting function along the longitudinal axis.
2Ease of manufacture
If additional bobbins are used to hold the coil, then the coil is securely retained, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent extracts the bobbin component from the design by providing integral retaining structures directly on the core. The core includes protrusions or recesses that directly retain the coil without requiring a separate bobbin, thereby eliminating an additional part and reducing manufacturing complexity while maintaining secure coil retention.
Solution Approach 2:
The coil retaining function is merged with the core structure itself. The core is designed with integrated features such as protrusions or recesses that serve both structural and retention functions, combining what would traditionally be separate components (core and bobbin) into a single integrated element.
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 allows for a more compact and cost-efficient assembly of switching devices by minimizing the width of the coil and core, facilitating easier manufacturing and improved magnetic flux distribution, thus enabling smaller and more efficient switching devices.
Implementation Method 1
A core for a coil of a switching device, in particular of an electromagnetic relay
Implementation Method 2
improved magnetic flux distribution
Data Source
AI summary
A core for a coil of a switching device includes an armature abutment section abutting an armature in a closed condition, an armature bearing section mounting the armature to the core, and a coil section receiving a coil and extending along a longitudinal axis from the armature abutment section to the armature bearing section. The coil section and at least one of the armature abutment section and the armature bearing section extend along separate planes offset from one another perpendicular to the longitudinal axis.