Single-Flange Bobbin Design for Symmetrical Coil Winding
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Solution Overview
Problem
Conventional inductive sensor bobbin designs with multiple flanges and sharp corners lead to irregular and asymmetric coil windings due to manufacturing artifacts, such as parting lines and flash, which can result in reduced performance and increased complexity in fitting the assemblies into small enclosures.
Innovation Solution
A bobbin design with a central hub and a single radially extending flange, eliminating end flanges to reduce overall height and allow for symmetrical coil assemblies to be wound on either side of the flange, which facilitates precise alignment and reduces temperature stability issues, and a coil winding method using a specialized arbor to maintain uniformity and symmetry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-flange bobbin designs are used, then structural support is provided, but manufacturing artifacts such as parting lines and flash cause irregular and asymmetric coil windings
Solution Approach 1:
The patent removes the end flanges from the bobbin structure, extracting the source of manufacturing artifacts (parting lines and flash) that cause coil winding asymmetry. This leaves only a single central flange, eliminating the harmful manufacturing defects while maintaining necessary structural support.
Solution Approach 2:
The patent intentionally creates an asymmetric bobbin design with a single central flange rather than symmetric multi-flange construction. This asymmetric configuration eliminates the parting lines and flash associated with multi-flange designs, thereby achieving symmetric and regular coil windings.
2Stability of the object's composition
If multiple flanges are used in bobbin design, then structural stability is maintained, but the overall height increases making it difficult to fit in small enclosures
Solution Approach 1:
The patent extracts and removes the end flanges from the traditional multi-flange bobbin design, reducing the overall height of the bobbin to enable fitting within compact sensor enclosures while retaining the central flange for necessary structural support and coil winding stability.
3Measurement precision
If conventional bobbin designs are used, then coil assemblies can be mounted, but alignment precision and temperature stability are reduced
Solution Approach 1:
The patent employs an asymmetric single-central-flange bobbin design that provides a unique positioning reference for coil assemblies, improving alignment precision. This configuration also enhances temperature stability by eliminating the thermal variability introduced by multiple flanges with different manufacturing tolerances.
Data Source
AI summary
A bobbin for holding inductive coils includes features that yield a smaller overall size and prevent irregular and asymmetric coil windings. The bobbin comprises a central hub and a single flange that extends from a middle circumference of the hub. The bobbin includes no end flanges at the ends of the central hub, reducing the height of the bobbin. The interface between the flange and the hub is a sharp corner with little or no radius, facilitating regular and symmetrical coil geometries. Coil assemblies can be attached to the respective two sides of the flange concentrically with the hub. Each coil assembly can be formed by winding a transmitter coil, then winding a receiver coil concentrically over the transmitter coil. Conductive pins that extend from the outer edge of the flange interface the coil lead wires to a printed circuit board of an inductive sensor or other device.