Voice Coil Actuator Coil-Bobbin Layout for High-Voltage Heat Control
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Solution Overview
Problem
Existing voice coil actuators face limitations in generating sufficient force while conforming to size and weight requirements, and they experience thermal issues when operating at high voltages and temperatures.
Innovation Solution
The voice coil actuator assembly incorporates a housing assembly, magnet assembly, and bobbin with dielectric coating, series-connected coils, and features like triply periodic minimal surface gyroid fins and lattice structures for improved heat management, allowing operation at high voltages and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If voice coil actuators operate at high voltages (e.g., 900V) and high temperatures (e.g., 400°C-800°C) to generate sufficient force, then force magnitude is improved, but thermal issues with permanent magnets occur
Solution Approach 1:
The patent segments the coil assembly into multiple coils wound on a single bobbin, with each coil disposed within a different winding cavity. This segmentation allows for better heat distribution and management across the permanent magnets, preventing excessive temperature concentration in any single magnet while maintaining the required force output at high voltages.
Solution Approach 2:
The patent introduces a ferrous steel back-iron as an intermediary component between the permanent magnets and the coil assembly. This back-iron serves as a thermal management element that helps dissipate heat from the permanent magnets, enabling the actuator to operate at high voltages and temperatures without overheating the magnets.
2Force
If voice coil actuators are designed to generate high-magnitude force, then force output is improved, but size and weight requirements may not be met
Solution Approach 1:
The patent merges multiple coils onto a single bobbin structure, with each coil occupying a separate winding cavity. This consolidation achieves high-magnitude force output through the combined effect of multiple coils while maintaining a compact, integrated structure that meets size and weight requirements.
Solution Approach 2:
The patent employs a composite structure combining ferrous steel back-iron with permanent magnets arranged in alternating polarity patterns. This composite material approach maximizes force density, allowing the actuator to generate high-magnitude force while minimizing the overall size and weight of the moving components.
3Force
If voice coil actuators are designed to generate high-magnitude force, then force output is improved, but size and weight requirements may not be met
Solution Approach 1:
The patent utilizes three-dimensional winding cavities within the bobbin structure, allowing coils to be arranged in multiple spatial dimensions rather than a single linear arrangement. This dimensional optimization enables high force output within a compact volume, meeting size requirements while maintaining force magnitude.
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 design enhances force generation and thermal management, enabling reliable operation at high voltages and temperatures, reducing permanent magnet temperatures by up to 115°C.
Implementation Method 1
When the coil is supplied with current, the electromagnetic field interacts with the magnetic field and generates a force in a direction that is perpendicular to the direction of current flow in the coil
Implementation Method 2
the electromagnetic field interacts with the magnetic field and generates a force
Implementation Method 3
Each winding cavity is at least partially coated with a dielectric coating material and has a bottom surface and two side walls. Each coil comprises magnet wire coated with the dielectric coating material
Data Source
AI summary
A voice coil actuator assembly includes a housing assembly, a magnet assembly, a bobbin, and a plurality of coils. The magnet assembly is disposed within, and is movable relative to, the housing assembly and includes a plurality of permanent magnets. The bobbin is fixedly mounted within the housing assembly and surrounds the magnet assembly. The bobbin includes a plurality of winding cavities. Each winding cavity is at least partially coated with a dielectric coating material and has a bottom surface and two side walls. The coils are electrically connected in series. Each coil is wound on the bobbin and is disposed, one each, within a different one of the winding cavities. Each coil comprises magnet wire coated with the dielectric coating material. When the coils are electrically energized, a linear force is generated that causes relative motion between the magnet assembly and the housing assembly.