Toroidal Inductor Winding Using Pre-Bent U-Shaped Conductors
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Solution Overview
Problem
Conventional methods for winding toroidal cores with thicker wires face challenges due to high mechanical stress, which can damage the core and require stronger housings or multi-core strands, leading to increased costs and poor high-frequency behavior.
Innovation Solution
The use of pre-bent U-shaped conductor sections that are mechanically and electrically connected to form a winding around a soft magnetic ring core, allowing for thicker wire diameters without deforming the core, using a connection technology that minimizes force on the core and maintains low resistance electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional winding techniques are used with thicker wires, then current carrying capacity is improved, but mechanical stress on the core increases causing damage or deformation
Solution Approach 1:
The winding is divided into multiple individually windable segments or sections along the core. Each segment can be wound separately with appropriate tension control, preventing excessive mechanical stress on the core while achieving the required current carrying capacity through the combined effect of multiple segments.
Solution Approach 2:
The winding segments are pre-formed or pre-positioned on the core before final assembly. This preliminary arrangement allows for controlled application of tension and ensures proper positioning without subjecting the core to excessive forces during the winding process.
2Strength
If stronger plastic housings are used to withstand higher tensile forces, then core protection is improved, but costs and overall size increase
Solution Approach 1:
The winding system is segmented into multiple sections that distribute mechanical stresses along the core-housing structure. This segmentation allows the housing to withstand tensile forces through distributed support rather than requiring a single heavily reinforced structure, reducing both weight and cost.
3Ease of manufacture
If multi-stranded conductors are employed to improve tensile force distribution, then winding feasibility is improved, but high-frequency performance deteriorates due to increased capacitance
Solution Approach 1:
Instead of using multi-stranded conductors that increase capacitance, the invention segments the winding into multiple separate turns or sections. Each segment uses solid conductors with acceptable tensile properties, maintaining low inter-winding capacitance while distributing mechanical stresses through the segmented structure.
Solution Approach 2:
The solution transitions from addressing tensile force distribution through conductor structure (multi-stranded) to addressing it through spatial arrangement (segmented winding sections). This dimensional shift allows solid conductors to be used, preserving high-frequency performance while achieving force distribution through proper winding geometry and segmentation.
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
Enables the use of thicker wires while maintaining core integrity and improving high-frequency performance, with reduced production costs and accessible connection points for reliable assembly and testing.
Implementation Method 1
an inductive effect is generated when a voltage is applied across the winding
Data Source
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AI summary
The invention relates to an inductive component, which has an annular core having a core cross section and made of a soft-magnetic material and a coil surrounding the core, the coil being composed of two electrically conductive sections. The sections each have a basic U shape with two limbs, of which the first limb is longer than the second limb and the first limb is curved and towards the end of same projects away from a plane defined by the basic U shape. The sections are pushed onto the core next to one another so that the basic U shape of each section surrounds the core cross section on three sides. The first limb of a section is mechanically and electrically connected to the second limb of the other section. A method for producing a component of this kind is also described.