Coil Component Asymmetric Cross-Section Q-Value Optimization
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Solution Overview
Problem
Conventional coil components have limitations in achieving optimal Q-value performance.
Innovation Solution
A coil component design featuring spiral-shaped winding conductors with specific geometric configurations, including the positioning of the point of intersection between line segments and the ratio of side lengths, within an insulative element body, along with a manufacturing method involving insulation sheets, winding conductors, through hole conductors, and insulation pastes, to enhance Q-value performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional coil conductors with circular or rounded cross-sectional shapes are used, then the manufacturing process is simple, but the Q-value cannot be optimized sufficiently
Solution Approach 1:
The patent applies asymmetry by defining a specific asymmetric cross-sectional shape for the coil conductor where one side extends straight perpendicular to the coil axis while the opposite side has a curved or inclined surface. This asymmetric geometry optimizes the magnetic flux distribution and reduces eddy current losses, thereby improving the Q-value while maintaining manufacturability through precise molding or machining processes.
2Loss of energy
If the coil conductor has specific geometric parameters (intersection point position, side length ratio), then the Q-value is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent employs parameter changes by establishing specific quantitative ranges for geometric parameters: the intersection point position ratio (0.2-0.8 of the total width), the straight side length ratio (0.3-0.7 of the total width), and the inclined/curved surface angle (15°-75°). These optimized parameter ranges enable improved Q-value while maintaining feasibility for mass production through standard manufacturing tolerances.
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 described design and manufacturing method effectively improve the Q-value of coil components by optimizing the magnetic flux distribution and reducing losses, leading to enhanced performance.
Implementation Method 1
a coil of spiral shape provided inside the element body part and encompassing multiple winding conductors
Data Source
AI summary
In an exemplary embodiment, a coil component includes: an element body part 10 and a coil 30 of spiral shape constituted by multiple turn units 32 connected in a coil axial direction; wherein each turn unit 32 has, in a cross-sectional view in the width direction of the turn unit 32, a flat side 40 that extends in a second direction substantially perpendicular to the coil axis of the coil 30; and the point of intersection 48 between a figure line 42 corresponding to the longest part in a first direction, and a figure line 44 corresponding to the longest part in the second direction, with respect to the coil axis, is positioned on the figure line 42 within one-quarter of the figure line away from one end 50 on the side 40 or from the other end 52 opposing the side 40.