Rectangular Wire Coil With Edgewise Winding For Miniaturization

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Solution Overview

Problem

Conventional reactor coils face challenges in miniaturization due to space occupation, complexity in manufacturing processes, reliability issues, and variations in electrical characteristics, primarily caused by the need for welding and folding of coupling portions and the protrusion of communicating terminals.

Innovation Solution

A coil configuration where multiple coil elements are formed with parallel alignment and reversed winding directions, eliminating the need for welding and folding by using edgewise and rectangular winding of a rectangular wire rod, allowing for continuous stacking and bending to reduce space occupation and enhance reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If individual windings are coupled via communicating terminal, then electrical connection is achieved, but space occupation increases and manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcoil space occupation

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent merges the coupling portion with the winding structure itself by forming the coupling portion as an integral part of the winding process. The coupling portion is created by folding back the end of the winding, eliminating the need for separate communicating terminals and reducing space occupation while maintaining electrical connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the communicating terminal from the structure by eliminating it entirely. Instead of using separate terminals for coupling, the winding itself is folded back to create the coupling portion, removing the unnecessary component and reducing overall coil volume.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If welding is performed on coupling portions, then electrical connection is achieved, but manufacturing complexity and process steps increase

Engineering Contradiction:

Improvewelded portion reliabilityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the coupling function with the winding structure by folding back the winding end to form the coupling portion. This integration eliminates the need for separate welding operations, as the coupling is achieved through the folded structure itself, thereby simplifying the manufacturing process while maintaining connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent maintains continuous winding action without interruption for coupling operations. The winding process continues seamlessly as the end is folded back to form the coupling portion, eliminating the need to stop for welding operations and thus simplifying the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

3Volume of stationary object

If folding is performed on coupling portion, then space occupation is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvecoil space occupationVSAvoidfolding process complexity

Core Design Contradiction:

Volume of stationary objectVSEase of manufacture

Solution Approach 1:

The patent merges the folding operation with the winding process itself. The coupling portion is formed by folding back the end of the winding during the winding process, combining two operations into one and eliminating the need for separate folding steps, thus reducing space occupation without increasing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs the folding action preliminarily as part of the winding process. The end of the winding is folded back to form the coupling portion before final assembly, preparing the structure in advance and eliminating the need for subsequent folding operations.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If communicating terminal and end portion protrude outside, then electrical connection is achieved, but reactor size increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidreactor dimensions

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent merges the coupling portion with the winding structure by folding back the winding end. This integration allows the coupling to be contained within the coil's external shape, eliminating protrusions and reducing reactor dimensions while maintaining electrical connection reliability through the folded structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10964470B2Coil and method for forming a coil

Publication Date: 2021.03.30 TAMURA KK

AI summary

A coil includes first and second coil elements both of which are formed by feeding one piece of a rectangular wire rod by a predetermined amount and winding rectangularly in an edgewise manner using winding heads, the first and second coil elements being wound in opposite directions from each other. A winding terminating end point of the first coil element is bent approximately 90 degrees in a direction opposite to a winding direction of the first coil element, and is connected to a winding terminating end point of the second coil element in a same flat plane. The second coil element includes an offset portion of the rectangular wire rod that is offset in a plan view from a side of the second coil element.