Toroidal Coil Unit With Positioning Parts For Consistent Noise Filtering
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Solution Overview
Problem
Conventional coil units with toroidal cores and bifilar windings exhibit variations in characteristics, requiring individual selection based on specific electronic devices for precise noise removal, which complicates high-precision signal control.
Innovation Solution
A coil unit design featuring a toroidal core with an annular shape and two coils wound in a bifilar configuration, utilizing positioning portions to accurately start and end the winding, preventing direct contact between the coils and ensuring consistent characteristics across multiple units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coil units are manufactured without positioning portions, then manufacturing process is simple, but characteristics vary among individual units requiring selective use
Solution Approach 1:
Positioning portions are provided on the toroidal core before winding the bifilar coil, defining specific start and end positions for the winding process. This preliminary positioning ensures that each coil unit is manufactured with consistent characteristics without requiring complex post-manufacturing adjustments or selective sorting.
Solution Approach 2:
The toroidal core with integrated positioning portions serves itself by automatically defining the correct winding start and end positions during the manufacturing process. The positioning portions guide the winding process to produce consistent characteristics across all units without requiring external intervention or complex manufacturing equipment.
2Measurement precision
If individual coil units are characterized and selectively used, then noise removal precision is improved, but device complexity and selection process increase
Solution Approach 1:
By providing positioning portions on the toroidal core that define specific winding start and end positions, the invention ensures that all coil units have uniform structure and consistent characteristics. This homogeneity allows any coil unit from the production line to be used without individual characterization or selective sorting, while still achieving high noise removal precision.
3Productivity
If bifilar winding is wound without positioning portions, then manufacturing process is faster, but resonance frequency characteristics vary among units
Solution Approach 1:
Positioning portions are pre-formed on the toroidal core to define the exact start and end positions for bifilar winding. This preliminary action guides the winding process to complete quickly while ensuring consistent resonance frequency characteristics across all manufactured units.
Solution Approach 2:
The positioning portions act as intermediaries between the toroidal core and the bifilar winding process, providing reference points that ensure consistent winding geometry and resonance frequency characteristics without slowing down the manufacturing process.
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 design achieves consistent resonance frequency characteristics and impedance profiles, allowing for selective use in circuits with varying noise frequencies, thereby enhancing precision in noise removal without the need for individual unit characterization.
Implementation Method 1
a coil unit including a toroidal core (11) and two coils (12) The two coils (12) are wound over the toroidal core (11) in a circumferential direction thereof to form a bifilar winding
Implementation Method 2
The positioning portion (11B) defines a winding-start positioning part (11C) and a winding-end positioning part (11D) each in contact with the bifilar winding at the winding-start portion and the winding-end portion
Data Source
AI summary
A coil unit including an annular toroidal core, two coils wound over the toroidal core providing a bifilar winding, a winding-start positioning part, and a winding-end positioning part. The winding-start positioning part is adapted for making contact with a winding-start portion of the coils. The winding-end positioning part is adapted for making contact with a winding-end portion of the coils for regulating the positions of the winding-start portion and the winding-end portion relative to the toroidal core.