Coil Component Radial Slit Current Distribution
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Solution Overview
Problem
Existing coil components with spiral planar conductors face challenges in reducing DC and AC resistance while maintaining even current density distribution between inner and outer peripheral sides, as increasing conductor width or using spiral slits alone does not sufficiently address these issues.
Innovation Solution
A coil component design featuring a first coil part spirally wound in one direction and a second coil part wound in the opposite direction, with the innermost turns of both coil parts radially divided by spiral slits, allowing connections between inner and outer peripheral conductor parts to balance current density distribution, and optionally formed on opposite surfaces of an insulating film with through hole conductors for connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the width of the spiral planar conductor is made large to reduce DC resistance and AC resistance, then the resistance decreases, but the current density distribution becomes uneven
Solution Approach 1:
The innermost turn of the spiral planar conductor is divided into multiple conductor parts (first, second, third, and fourth conductor parts) by spiral slits. This segmentation allows the current to be distributed more evenly across different radial positions, preventing current concentration at the outer periphery while maintaining a large overall conductor width for low resistance.
2Manufacturing precision
If spiral slits are used to divide the planar conductor into multiple parts to improve current density distribution, then current density uniformity improves, but a difference in current density distribution remains between inner and outer peripheral sides
Solution Approach 1:
The patent combines multiple conductor parts (first, second, third, and fourth conductor parts) that are radially divided by spiral slits and connects them through radial connections. This merging approach maintains the current distribution benefits of segmentation while providing additional current paths that reduce overall resistance by allowing current to flow through multiple parallel paths.
3Manufacturing precision
If the innermost turn is radially divided into multiple conductor parts by spiral slits, then current density distribution improves, but DC resistance and AC resistance cannot be reduced sufficiently
Solution Approach 1:
The patent introduces radial connections that extend the current paths in the radial dimension, connecting inner and outer conductor parts. This dimensional approach creates multiple current flow paths through the thickness/radial direction of the conductor, effectively reducing resistance while maintaining the current distribution benefits of the spiral slit division.
Data Source
AI summary
Disclosed herein is a coil component that includes first and second coil parts each spirally wound in a plurality of turns in directions opposite to each other. An innermost turn of the first coil part is radially divided into first and second conductor parts by a spiral slit, and at least an innermost turn of the second coil part is radially divided into third and fourth conductor parts by a spiral slit. The first conductor part is positioned radially inward of the second conductor part, and the third conductor part is positioned radially inward of the fourth conductor part. The inner peripheral end of the first conductor part is connected to the inner peripheral end of the fourth conductor part, and the inner peripheral end of the second conductor part is connected to the inner peripheral end of the third conductor part.