Coil Component Variable Insulation Layer Design
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Solution Overview
Problem
Traditional coil components with bifilar winding experience untidy winding due to differences in covering film thickness, leading to unstable properties and performance dispersion.
Innovation Solution
The coil component design features wires with decreasing outer diameters and thinner covering films in each layer, ensuring proper tension and alignment, with the outer diameter of the conductor remaining constant across layers, to prevent untidy winding and stabilize the layered structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires with different covering film thicknesses are used in bifilar winding, then the wire structure can accommodate different insulation requirements, but the winding becomes untidy and wire alignment is compromised
Solution Approach 1:
The patent applies different covering film thicknesses to different layers locally - the first layer wire has a first covering film thickness while the second layer wire has a second covering film thickness that is different from the first. This local differentiation allows each layer to have optimized insulation properties while maintaining overall winding integrity through controlled outer diameter relationships.
Solution Approach 2:
The patent changes the covering film thickness parameter between layers to solve the contradiction. By setting the outer diameter of the second layer wire smaller than the first layer wire through different covering film thicknesses, the patent achieves both proper insulation (reliability) and maintains tidy winding structure (shape) by compensating for the thickness difference through outer diameter control.
2Reliability
If the outer diameter of wires in the second layer is made smaller to compensate for covering film thickness differences, then wire alignment improves, but the conductor outer diameter must be reduced which affects electrical properties
Solution Approach 1:
The patent applies different outer diameter reductions locally to different layers. The first layer wire maintains a larger outer diameter while the second layer wire has a smaller outer diameter, but this is compensated by ensuring the conductor cross-sectional areas are equal. This local differentiation in outer diameter with equal conductor areas achieves both structural stability and electrical property preservation.
Solution Approach 2:
The patent changes the outer diameter parameter of the wire structure while maintaining the conductor cross-sectional area constant. By adjusting only the covering film thickness and outer diameter parameters without changing the conductor size, the patent achieves proper layer alignment while preserving electrical properties such as resistance and current carrying capacity.
Data Source
AI summary
A coil component has a winding core part, and a plurality of wires that are wound on the winding core part to form a plurality of layers. The wires each include a conductor and a covering film that covers the conductor, an outer diameter of the wire of an n-th layer (“n” is an integer that is two or greater) is smaller than an outer diameter of the wire of an (n−1)th layer, an outer diameter of the conductor of the wire of the n-th layer is equal to an outer diameter of the conductor of the wire of the (n−1)th layer, and a thickness of the covering film of the wire of the n-th layer is smaller than a thickness of the covering film of the wire of the (n−1)th layer.