Coil Component Pressing Member for Stable Coupling
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Solution Overview
Problem
In the miniaturization of coil components, there is a challenge in maintaining a constant coupling coefficient between primary and secondary coils due to human error in winding, leading to inconsistent coil turns and positions, which complicates the manufacturing process and affects insulation.
Innovation Solution
A coil component design featuring a multilayer substrate with a conductor pattern, a wire-coiled secondary part stacked with the primary part, and a core that penetrates through both, along with a pressing member to ensure close adherence and consistent spacing, maintaining a stable coupling coefficient and reducing leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual winding is used to form coils, then flexibility in coil formation is improved, but manufacturing precision deteriorates due to human error causing inconsistent coil turns and positions
Solution Approach 1:
The patent replaces manual mechanical winding with automated wire winding machinery. The wire winding apparatus uses precision mechanisms to wind the wire around the bobbin with controlled tension and speed, ensuring consistent coil turns and positions without human error. This substitution maintains manufacturing flexibility while dramatically improving precision.
Solution Approach 2:
The patent controls critical winding parameters such as wire tension, winding speed, and bobbin rotation speed through automated systems. By precisely controlling these parameters, the system ensures consistent coil geometry and positioning. The wire tension control mechanism maintains constant tension during winding, while the bobbin rotation system ensures uniform angular velocity, both contributing to manufacturing precision.
2Volume of moving object
If coil components are miniaturized, then device size is reduced, but insulation between windings and core becomes more difficult to maintain
Solution Approach 1:
The patent employs composite insulation structures combining multiple materials with different properties. The insulation system includes a bobbin made from insulating material, additional insulation layers wrapped around the coil windings, and a core with insulating coatings. This multi-material approach provides sufficient electrical insulation even in miniaturized components where spacing is reduced.
Solution Approach 2:
The patent addresses insulation challenges by utilizing the radial dimension between the core and outer windings. By optimizing the radial spacing and using the bobbin structure to maintain this dimensional separation, the design ensures adequate insulation clearance. The pressing member also utilizes axial pressure to maintain consistent spacing between layers, effectively using the axial dimension to preserve insulation properties.
3Power
If coupling coefficient between primary and secondary coils is increased, then power transfer efficiency is improved, but leakage inductance increases which affects performance
Solution Approach 1:
The patent applies different structural characteristics to different regions of the coil assembly. The primary and secondary windings are positioned with specific local spacing and orientation to optimize magnetic coupling in the core region while maintaining appropriate clearance in other areas. This localized optimization allows high coupling coefficient where needed while controlling leakage inductance through strategic spacing and shielding structures.
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 ensures a consistent coupling coefficient between the primary and secondary coils, decreases leakage inductance, simplifies the manufacturing process, and reduces manufacturing costs by eliminating the need for a bobbin winding process.
Implementation Method 1
a core coupled to the first and second coil parts while penetrating through the first and second coil parts to thereby be electromagnetically coupled to the first and second coil parts
Implementation Method 2
a pressing member interposed between the core and the second coil part to allow the first and second coil parts to closely adhere to each other
Data Source
AI summary
A coil component includes a first coil part including a multilayer substrate on which a conductor pattern is formed, a second coil part formed as a wire and stacked together with the first coil part, a core coupled to the first and second coil parts while penetrating through the first and second coil parts to thereby be electromagnetically coupled to the first and second coil parts, and a pressing member interposed between the core and the second coil part to allow the first and second coil parts to closely adhere to each other.