Coil Component Odd Turn Count and Resistance Reduction
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Solution Overview
Problem
Existing coil components struggle to set the total number of turns to an odd number when the number of turns of each coil part is an integer value, making it difficult to fine-tune parameters like inductance or resistance.
Innovation Solution
A coil component design featuring a first and second coil part with specific turn connections and conductor width configurations, allowing the total number of turns to be set to an odd number by connecting inner and outer peripheral turns, and using spiral-shaped slits to separate turns into multiple lines for uniform current density distribution and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the number of turns of each coil part is set to an integer value, then the manufacturing is simplified, but the total number of turns cannot be set to an odd number, limiting parameter adjustment flexibility
Solution Approach 1:
The coil component is divided into a first coil part and a second coil part, each with an integer number of turns. By segmenting the coil into multiple parts with different connection configurations (series or parallel), the patent enables flexible total turn number adjustment while keeping each individual coil part's turn number as an integer for manufacturing simplicity.
Solution Approach 2:
The patent introduces a new dimension of configuration by connecting the inner peripheral ends and outer peripheral ends of the two coil parts in different ways (series connection vs. parallel connection). This dimensional change in connection topology allows the total effective turns to be adjusted flexibly even when each coil part has an integer number of turns.
2Ease of manufacture
If the conductor width is kept uniform across all turns, then the manufacturing is easier, but the effective conductor width variation between turns increases, affecting performance
Solution Approach 1:
The patent applies different conductor widths to different turns based on their local requirements. Specifically, the inner peripheral turns have a smaller conductor width than the outer peripheral turns. This local quality adjustment compensates for the effective conductor width variation caused by the spiral geometry, improving manufacturing precision.
3Device complexity
If the turns are not separated into multiple lines, then the structure is simpler, but the current density distribution is non-uniform, increasing resistance
Solution Approach 1:
Each turn is segmented into multiple lines (e.g., first line and second line) by introducing spiral-shaped slits. This segmentation of turns into multiple parallel current paths uniformizes the current density distribution across the conductor cross-section, reducing both DC resistance and AC resistance while maintaining structural simplicity.
Data Source
AI summary
Disclosed herein is a coil component that includes a first coil part spirally wound in a plurality of turns, the first coil part including a first turn positioned at an innermost periphery and a second turn positioned on an outer peripheral side relative to the first turn; and a second coil part spirally wound in a plurality of turns, the second coil part including a third turn positioned at an innermost periphery and a fourth turn positioned on an outer peripheral side relative to the third turn. The first turn and the fourth turn are connected to each other, and the second turn and the third turn are connected to each other.