Alpha-Wound Inductor Coil With Widened Transition for Shape Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductors with alpha-winding coils face challenges in maintaining shape due to reduced adhesion regions when the number of turns is minimized, leading to loosening issues, especially with 2.5 turns or less, as the principal surfaces of the conductive wire provide insufficient adhesion.
Innovation Solution
A coil design featuring a conductive wire with an insulating cover and a widened transition section, where the width of the conductive wire is increased at the transition area, enhancing adhesion between turns and maintaining the coil's shape, while the lead-out portions are taken from the outermost turns, ensuring structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of turns is reduced to minimize inductor size, then the inductor size is reduced, but the adhesion region of adjacent turns decreases making it difficult to maintain coil shape
Solution Approach 1:
The conductive wire is designed with non-uniform cross-sectional dimensions: the first section (adhesion region) has a larger width than the second section (lead-out region). This local quality variation ensures that the adhesion region provides sufficient bonding area to maintain coil shape, while the lead-out region maintains standard dimensions for proper electrical connection.
Solution Approach 2:
The width parameter of the conductive wire is changed between different sections. The first section has a width W1 that is larger than the width W2 of the second section. This parameter change increases the adhesion region area to prevent coil loosening while keeping the overall inductor size compact.
2Productivity
If the number of turns is reduced to meet size reduction demands, then productivity is improved, but the adhesion region becomes insufficient leading to coil loosening
Solution Approach 1:
The conductive wire features a localized quality enhancement in the first section where the width is increased to provide sufficient adhesion region. This allows the coil to maintain reliability with fewer turns, as the enhanced adhesion region prevents loosening even when the total number of turns is reduced for size efficiency.
3Strength
If the conductive wire width is increased at the transition section, then bonding strength between turns is enhanced, but the wire cross-sectional area increases
Solution Approach 1:
The conductive wire is designed with localized quality enhancement only in the first section (adhesion region) where the width is increased to W1. The second section (lead-out region) maintains the standard smaller width W2. This approach concentrates the additional material only where it is needed for bonding strength, minimizing the overall increase in material quantity.
Solution Approach 2:
The width parameter of the conductive wire is selectively changed only in the first section to enhance bonding strength. The width W1 in the adhesion region is larger than the width W2 in the lead-out region. This parameter change is localized to minimize material consumption while achieving the required bonding strength.
Data Source
AI summary
A coil includes a winding section that are formed by winding a conductive wire having an insulating cover and a pair of opposite principal surfaces into an upper stage and a lower stage that are connected to each other by an innermost turn of the conductive wire that serves as a transition section while both ends of the conductive wire are located at an outermost turn of the conductive wire. The coil also includes a pair of lead-out portions that are taken from respective outermost turns of the upper stage and the lower stage and that continue to respective ends of the conductive wire. In the coil, at least part of the transition section includes a widened portion, and a width of the widened portion of the conductive wire is greater than a width of the conductive wire at a position other than the widened portion.