Toroidal Coil Lead Formation via Wire Twist and Posture Change
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Solution Overview
Problem
The existing manufacturing methods for toroidal coil devices are complicated and require significant force to form lead parts due to the conductive wire's rectangular cross-section, making it difficult to transform the wire into a linear shape for connection with a substrate.
Innovation Solution
A method involving a conductive wire with a height dimension greater than its width, where the wire is wound around a core in a lying posture to form a twist part and then wound in a standing posture to create a winding portion, allowing for easy formation of lead parts by minimizing the second moment of area involved in transformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductive wire with rectangular cross-section is wound around the core and then transformed into a linear shape to form lead parts, then the coil device can be manufactured, but a great force is required and the transformation becomes extremely difficult
Solution Approach 1:
The patent applies preliminary action by forming the twist part at the tip end of the conductive wire before winding the wire around the core. This preliminary twisting creates a pivot point that facilitates subsequent transformation of the wire into a linear lead part shape, reducing the force required during the transformation step.
Solution Approach 2:
The patent changes the physical state and orientation parameters of the conductive wire by creating a twist part that alters the wire's configuration. This parameter change from a straight wire to a twisted wire with a pivot point enables easier transformation into the lead part shape, addressing the force requirement issue.
2Shape
If the conductive wire is wound around the core in a standing posture, then the coil structure is formed, but the second moment of area is large making transformation difficult
Solution Approach 1:
The patent segments the conductive wire into distinct functional portions: a tip end part that forms the twist part and lead part, and a winding portion that forms the coil. This segmentation allows the tip end to be transformed with minimal second moment of area while the winding portion maintains the necessary coil structure.
Solution Approach 2:
The patent applies local quality by creating a twist part at the local tip end region of the conductive wire, while the rest of the wire maintains its winding configuration around the core. This localized modification enables easy transformation of the lead part without affecting the overall coil structure.
3Ease of manufacture
If a rotational drive mechanism is used to wind the air core coil around the ring-like core, then the coil can be formed, but the mechanism becomes complicated
Solution Approach 1:
The patent applies preliminary action by pre-forming the twist part at the tip end of the conductive wire before the winding process. This preliminary preparation simplifies the winding mechanism requirements, as the twist part naturally facilitates the winding process without requiring complex rotational drive mechanisms or transformation apparatus.
Data Source
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AI summary
A method for manufacturing a coil device comprises a first step of twisting a tip end part of the conductive wire 21 by 90 degrees or approximately 90 degrees with respect to a conductive wire portion arranged rearward continuously from the tip end part to form a twist part 3, and winding the tip end part of the conductive wire 21 around the outer peripheral surface of the core 1 in a lying posture on the outer peripheral surface; a second step of winding the conductive wire 21 arranged rearward continuously from the twist part 3 around the outer periphery surface of the core 1 in a standing posture on the outer peripheral surface; and a third step of transforming the conductive wire 21 on a tip end side with respect to the twist part 3 in a direction apart from the outer periphery surface of the core 1 to form one lead part 4 extending substantially linearly, and forming the other lead part 5 by the conductive wire 21 arranged rearward continuously from the winding portion 22.