Toroidal Inductor Coiled Wire Nest With Staggered Teeth
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Solution Overview
Problem
Current toroidal inductor designs face issues with non-uniform spacing and distance between coils, leading to decreased resonance and efficiency due to lack of uniformity in coil configuration, which affects impedance and inductance.
Innovation Solution
A coiled wire nest with a vertically stacked configuration and staggered teeth on a vertical disc inserted into a latitudinal center hub, ensuring identical wire length and configuration across layers, and consistent spacing between coils, forming a center through-nest for stable impedance and resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional toroidal coil configurations are used, then inductance can be achieved, but non-uniform spacing between coils leads to decreased resonance and efficiency
Solution Approach 1:
A plastic disc with equidistantly spaced teeth is introduced as an intermediary component between the coil windings. The teeth act as spacers that maintain uniform distance between adjacent coils, ensuring consistent spacing throughout the toroidal structure. This mediator component solves the manufacturing challenge of achieving precise uniform spacing while maintaining resonance stability.
Solution Approach 2:
The plastic disc with pre-spaced teeth is prepared in advance before coil winding. The equidistant teeth are预先 positioned to define the exact spacing required for optimal resonance. By establishing the spacing structure beforehand, the coil windings can be wrapped uniformly around the teeth, ensuring consistent coil distance without requiring post-manufacturing adjustment.
2Quantity of substance
If ferromagnetic core materials are used to increase inductance, then inductance value increases, but eddy current losses occur within the core
Solution Approach 1:
The patent applies different material properties to different regions of the core structure. Ferrite material is used in specific localized areas where magnetic field concentration is needed to enhance inductance, while air gaps are maintained in other regions to prevent eddy current formation. This selective material distribution allows the system to achieve high inductance values while minimizing energy losses from eddy currents.
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
This configuration achieves stable impedance and resistance for circuit integration, enhances energy amplification, and increases inductance by maintaining uniform spacing and progression in the winding pattern, improving overall electrical performance.
Implementation Method 1
increased electro-magnetism and inductance
Implementation Method 2
the magnetic field generated by the coiled wire nest circulates through the toroidal core
Implementation Method 3
achieves stable impedance and resistance for circuit integration
Data Source
AI summary
Provided are claims and disclosure for a toroidal coil apparatus comprising a coiled wire nest further comprising: a top end layer disposed with a center through-layer; a circumferential side wall; a bottom end layer disposed with a center through-layer any one of a top end layer or bottom end layer radially extending through the circumferential side wall to form a vertically stacked coiled wire nest with a center through-nest, wherein the wire length and configuration of each stacked layer is identical and the distance between adjacent coiled wire is identical; at least a single or a plurality of inputs of at least two counter-directional channels in electrical communication with the coiled wire nest and at least a single or plurality of outputs of at least two counter-directional channels; and a coiled wire nest frame, further comprising: a latitudinal center hub with a plurality of slots; a vertical disc with a plurality of slots with staggered teeth; wherein the said vertical disc with staggered teeth is inserted into each slot of the said latitudinal center hub; the said staggered teeth are configured to shape a coiled wire nest with at least two stacked layers of wire with a crossed winding pattern, wherein the wire length and configuration of each stacked layer is identical and the distance between adjacent coiled wire is identical; and a vacuous center in communication with the center through layer of the top end layer and bottom end layer to shape the center through-nest of the coiled wire nest.