Coil Component Parallel Connection Without Wire Twisting
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Solution Overview
Problem
Conventional coil devices with twisted flat wires between coil elements face challenges in downsizing due to increased gap distance, leading to deteriorated magnetic properties and higher manufacturing costs due to the need for additional support structures.
Innovation Solution
The coil component features a design where the flat wire is folded and connected with raised and bent parts at right angles to eliminate twisting between coil elements, allowing for closer spacing without additional support members, thereby maintaining magnetic properties and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flat wire is twisted by 180 degrees between two coil elements to connect them, then the coil elements can be connected in parallel, but the distance between the two coil elements is expanded and the magnetic property deteriorates
Solution Approach 1:
The flat wire is extended in the radial direction (another dimension) to connect the two coil elements, rather than twisting it between them. This allows the wire to bypass the gap between coils, connecting the elements without expanding the distance between them, thus maintaining magnetic properties while achieving parallel connection.
2Ease of manufacture
If the flat wire is drawn from one coil element to another with twisting, then the coil elements can be interconnected, but additional support structures are required and manufacturing cost increases
Solution Approach 1:
The harmful twisting action is extracted and eliminated from the design. Instead of twisting the flat wire between coil elements, the wire is extended radially outward from one element and connected to the other, removing the need for additional support structures to hold the twisted wire in place.
3Volume of moving object
If the gap between two coil elements is reduced for downsizing, then the device size is reduced, but the magnetic property deteriorates
Solution Approach 1:
The connection path of the flat wire is moved to the radial dimension, extending outward from the coil elements rather than passing through the gap between them. This allows the gap to be minimized for downsizing while the wire connection is maintained in the radial direction, preserving magnetic properties.
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
This design enables the downsizing of coil devices while maintaining magnetic performance and reducing manufacturing steps and costs by eliminating the need for additional support structures and minimizing insulation coating exfoliation.
Implementation Method 1
A coil component such as a reactor, for example, can generate an inductance with a structure where a winding coil is wound around a magnetic core.
Data Source
AI summary
A coil component 100 includes a first coil element 111 and a second coil element 112 each formed in an angular-tubular shape and disposed in parallel by winding and laminating a single flat wire 101 in one direction with edgewise-winding between one end portion 101A and another end portion 101B and bending the wound and laminated coil into two, and includes an interconnection part 113 for connecting the both elements. The interconnection part 113 includes a coil element winding end portion side raised part 123A, a coil element winding start portion side raised part 123B, and an intermediate part 123C extended between the two raised parts 123A and 123B.