Making the core for a three-segment air-coil

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Discussion Overview

The discussion revolves around designing a core for a three-segment air-coil, specifically focusing on the construction method and materials for a cylindrical core that allows for the winding of three separate coils. The conversation includes considerations for structural integrity and the feasibility of different materials.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Conceptual clarification

Main Points Raised

  • Jason O proposes using empty masking tape rolls as sections for the coil, with cardboard spacers for flanges, but expresses concern about the stiffness of cardboard for toroidal winding.
  • One participant seeks clarification on whether the coils are stacked or concentric, indicating potential confusion about the design.
  • Another participant suggests that using a single long tube might simplify construction compared to three short tubes, proposing various materials like cardboard cores from sign shops or cylindrical plastic items from hardware stores.
  • There is a light-hearted exchange regarding the nature of the experiments being conducted, with some participants joking about safety and the involvement of local authorities.

Areas of Agreement / Disagreement

Participants have not reached a consensus on the best method or materials for constructing the core, with multiple suggestions and some confusion about the design specifics remaining unresolved.

Contextual Notes

Participants have not fully explored the implications of material choices on the performance of the coils, and there are assumptions about the structural requirements that have not been explicitly stated.

Jdo300
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Hello All,

I am trying to come up with the simplest (but most effective way to make a core (cylinder that is 5"OD x 3"ID x 2" tall) and I want to make it so that is has two separators on it so I can wind three separate coils on the same core. In case that was extremely confusing, I made a diagram showing what I am going for. At the moment, my best idea is to use empty masking tape rolls for each section of the coil and glue it with cardboard spacers or something for the flanges. But I also plan on winding some wire toroidaly on it too and I'm not sure that cardboard would be stiff enough. What do you think?

- Jason O
 

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Are you talking about 3 coils stacked on top of each other with a 5" OD and 3" ID, or 3 concentric coils wherein the innermost has a 3" ID and the outermost has a 5" OD? :confused:
 
Alright, you little bugger... you altered your initial post after my response. Just for that, I'm going to bed now. Hope you're happy. This means that the rest of the toroid staging system sketches won't be up until tomorrow. :-p
 
lol, sorry about that. I posted and then went to bed, later realizing I forgot to attach the picture :-p
 
No worries, mate. :smile:
I'm quite confused now, though. Do you mean that you're going to do a toroidal wind around the whole unit after the initial wraps are in place? If so, why? :confused:
 
Yes, it is for some odd-ball experiments I'm doing
 
Intriguing. Does your local fire department know about you? :rolleyes:
 
Danger said:
Intriguing. Does your local fire department know about you? :rolleyes:

lol, hopefully I won't need them for anything
 
Okay, then. I'd hate to be aiding and abetting a menace to society. :biggrin:
I'm thinking that the construction would be simpler if you use one long tube rather than 3 short ones. I can think of a few different materials, such as the cardboard core that your local sign shop buys vinyl on. When I worked at one, we gave them away all the time. There are also all kinds of cylindrical plastic things available at hardware or variety stores, like candle holders, lamp shades, etc.. Hobby shops also carry a wide range of cardboard and plastic forms for moulding candles or latex or plaster casting. You can then just insert the form through your spacer rings and apply a touch of glue to keep everything in place. It would be a lot stronger than gluing the tubes together.
 

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