Toroidal Core Choke Insulation with Elastic Spreader
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Solution Overview
Problem
Existing insulating parts for toroidal core chokes face challenges in maintaining consistent insulation spacing and accommodating varying core diameters, leading to potential slippage of windings and inefficient use of space.
Innovation Solution
An insulating part with radially extending dividers and elastically deformable spreading parts that expand to create separate winding spaces, ensuring a fixed insulation spacing while allowing for adaptation to different core diameters, utilizing materials like polycarbonate for mechanical stability and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a narrow divider is used to maximize winding space, then the winding space is increased, but the insulation spacing reliability deteriorates
Solution Approach 1:
The insulating part incorporates an elastically deformable spreading part that can dynamically adjust its width. When compressed during assembly, it contracts to fit through the core hole, then expands radially to press against the inner wall, providing reliable insulation spacing. This dynamic behavior allows the divider to be narrow for maximizing winding space while still ensuring reliable insulation when expanded.
2Stability of the object's composition
If a rigid insulating part is used to ensure dimensional stability, then the insulation spacing is maintained, but the adaptability to varying core diameters deteriorates
Solution Approach 1:
The insulating part combines a rigid divider for dimensional stability with an elastically deformable spreading part for adaptability. The deformable portion can compress to accommodate different core diameters during assembly, then expand to provide consistent insulation spacing once installed. This dynamic characteristic enables the same insulating part to adapt to varying core diameters while maintaining stable insulation dimensions.
3Device complexity
If a simple insulating part is used to reduce complexity, then the device complexity is reduced, but the ability to prevent winding slippage deteriorates
Solution Approach 1:
The insulating part uses the elastic deformation mechanism to create a self-locking effect. When the spreading part expands and presses against the inner wall of the core, it generates friction force that prevents winding slippage. This dynamic expansion and pressure generation is achieved through a relatively simple structure, avoiding the need for complex locking mechanisms while effectively preventing slippage.
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
The solution provides a reliable and adaptable insulation system that maintains large winding spaces with consistent insulation spacing, preventing slippage and accommodating core diameter variations, thus enhancing the assembly and performance of toroidal core chokes.
Implementation Method 1
At least one of the spacers may be an elastically deformable part. The elastically deformable part may have a width that is large relative to the width W of the divider in a deformed state transverse to a radial direction
Data Source
AI summary
A toroidal core choke includes a toroidal core and an insulating part. The insulating part includes a separating device for separating winding spaces on the toroidal core. The separating device includes a divider and a spacer on an end of the divider. A width of the divider is less than a width of the spacer.