Toroidal Inductor with Clamping Insulating Insert
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Solution Overview
Problem
Existing inductor arrangements are not compact and require additional insulation after winding ends and connection wires are connected, leading to increased costs and complexity in manufacturing.
Innovation Solution
A toroidal inductor arrangement with an electrically insulating insert in its core that clamps the winding ends and connection wires, providing necessary insulation and maintaining a compact design, eliminating the need for additional insulation steps and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional insulation is provided after connection of winding ends and connection wires, then electrical insulation is ensured, but production steps increase and costs rise
Solution Approach 1:
The patent combines the insulation function with the connection structure by integrating insulation elements directly into the connection terminals and winding end holders. This merging eliminates the need for separate insulation steps after connection, as the insulation is already built-in to the structural components that hold and connect the winding ends.
Solution Approach 2:
The patent implements preliminary insulation by pre-installing insulation elements (such as insulation rings, insulation bars, or insulated terminal structures) before the winding ends and connection wires are connected. This preliminary action ensures that insulation is already in place when connections are made, eliminating the need for post-connection insulation steps.
2Reliability
If coil formers use traditional clamping arrangements, then winding ends are held securely, but the structure projects far beyond the dimensions of the coil former
Solution Approach 1:
The patent applies the nesting principle by placing the clamping structures and insulation elements inside the existing coil former boundaries. The connection terminals and insulation components are nested within the coil former's dimensional envelope, preventing any projection beyond the coil former's outer dimensions while still providing secure holding of the winding ends.
Solution Approach 2:
The patent transitions from traditional external clamping arrangements to an internal clamping system by utilizing the internal space and dimensional layout of the coil former. The clamping structures are positioned in a different spatial arrangement within the coil former's volume, allowing secure holding without external projection.
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 results in a compact, cost-effective inductor arrangement with integrated insulation, reducing production steps and ensuring reliable electrical insulation of winding ends and connection wires, thereby enhancing manufacturing efficiency.
Implementation Method 1
an electrically insulating insert (5) which is inserted in a clamping manner into the central opening (3)
Implementation Method 2
holding of the winding ends in the electrically insulating insert in clamping manner provides the necessary electrical insulation
Data Source
AI summary
A inductor arrangement has a toroidal core with a central opening, a winding which is arranged around the core and has two winding ends, and an electrically insulating insert which is inserted into the central opening in a clamping manner. Here, the winding ends are inserted into the insert in a clamping manner.