Toroidal Inductor Segmented Winding for Low-Volume Production
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Solution Overview
Problem
The manufacturing of non-standard toroidal inductors is expensive and time-consuming due to the requirement for specialist winding machines, making it costly for users who need small quantities.
Innovation Solution
A toroidal inductor design comprising first and second winding portions that can be easily connected to form coils around a toroidal core using standard apparatus, allowing for manual construction and easy modification or replacement, eliminating the need for specialized machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If specialist winding machines are used to manufacture toroidal inductors, then manufacturing precision and automation are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coil winding process is segmented into discrete components: a support structure with pre-formed conductive pathways and separate toroidal core. The conductive pathways are pre-configured on the support structure, eliminating the need for complex winding machines to create the coil geometry. This segmentation allows standard apparatus to be used while maintaining precision.
Solution Approach 2:
A support structure acts as an intermediary between the toroidal core and the final inductor assembly. The support structure carries the conductive pathways and provides a framework that simplifies the manufacturing process, allowing coils to be formed by connecting pre-configured pathways rather than winding wire around the core.
2Adaptability or versatility
If custom toroidal inductors are manufactured using specialist winding machines, then adaptability to non-standard designs is improved, but manufacturing time and cost increase
Solution Approach 1:
The inductor is divided into replaceable modules: toroidal core, support structure with conductive pathways, and coil windings. This modular approach allows easy customization by swapping modules rather than reconfiguring entire winding machines, significantly reducing lead time for custom designs.
Solution Approach 2:
The support structure with conductive pathways is prepared in advance using standard manufacturing processes. This preliminary preparation eliminates the need for time-consuming machine setup and programming when custom inductors are required, as the framework is already in place and ready for assembly.
3Manufacturing precision
If small quantities of toroidal inductors are produced using specialist winding machines, then manufacturing precision is maintained, but manufacturing cost per unit increases
Solution Approach 1:
By segmenting the inductor into pre-fabricated components (support structure with pathways, toroidal core, coil windings), small batch production becomes economically viable. Each component can be manufactured independently using standard, lower-cost processes, avoiding the need for expensive specialized winding machinery while maintaining quality.
Solution Approach 2:
The support structure acts as a disposable or reusable fixture that enables precise coil formation without requiring expensive, dedicated winding machines. This approach is particularly cost-effective for small production runs where the high fixed cost of specialist equipment cannot be amortized.
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 approach reduces manufacturing costs and time, enabling efficient production of custom designs at a lower cost and facilitating the construction of toroidal inductors without the need for expensive machinery, particularly beneficial for small quantities.
Implementation Method 1
Toroidal inductors are passive electronic components which include a toroidal shaped magnetic core around which a coil is wound
Implementation Method 2
The core is formed from a ferromagnetic material such as laminated iron, iron powder, or ferrite
Data Source
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AI summary
A toroidal inductor (20) comprising a toroidal core (22) and at least one coil (24, 26, 28) is disclosed. Each coil (24, 26, 28) comprises at least one first winding portion (54), and at least one second winding portion (30). At least one first winding portion (54) comprises at least one alpha electrical pathway (66) which extends between a first alpha pathway end (68) to a second alpha pathway end (70). At least one second winding portion (30) comprises at least one beta electrical pathway which extends between a first beta pathway end (30A) to a second beta pathway end (30B). The first and second winding portions (54, 30) are electrically connected to form at least one coil (24, 26, 28) wound around the toroidal core (22). Each coil (24, 26, 28) is comprised of a plurality of pathway units, and each pathway unit comprises an alpha electrical pathway (66) connected to a beta electrical pathway, the second alpha pathway end (70) is connected to the first beta pathway end (30A), and the second beta pathway end (30B) is connected to the first alpha pathway end (68) of the next pathway unit along the coil (24, 26, 28).