Coil Component with Varying Edge Distance for Leakage Flux Control
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Solution Overview
Problem
Existing coil components for resonance transformers, such as those used in liquid crystal display backlights, suffer from leakage flux issues that lead to eddy currents and associated heat and noise problems, and require additional materials like aluminum boards for insulation, which can compromise performance.
Innovation Solution
A coil component design featuring a core with opposing parts and side legs, a primary coil around the outer circumference of a middle leg, and a secondary coil with an egg-shaped winding, where the distance between the primary and secondary coil edges varies along the circumference, providing improved insulation and reduced leakage flux by lengthening the creeping distance between wires and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If aluminum board is implemented on upward and downward directions of the coil component to prevent leakage flux, then leakage flux is reduced, but exoergic of the coil is deteriorated
Solution Approach 1:
The patent divides the core into two opposing parts with side legs and a middle leg, creating a segmented structure that directs magnetic flux through specific paths. This segmentation allows the magnetic flux to be contained within the core structure rather than leaking outward, eliminating the need for aluminum shielding boards while maintaining low leakage flux.
Solution Approach 2:
The patent employs a nested coil structure where the secondary coil is wound around the primary coil, and both are positioned within the core structure. This nesting arrangement, combined with the varying distance between coil edges, creates effective magnetic coupling while containing the flux within the core, preventing leakage without requiring additional shielding materials that would affect coil performance.
2Length of stationary object
If coil component is made thinner to meet low profile requirements, then outward appearance is improved, but insulation between primary and secondary coils becomes more difficult
Solution Approach 1:
The patent applies local quality by making the distance between the outer perimeter edge of the primary coil and the inner perimeter edge of the secondary coil vary along the circumferential direction. Specifically, the distance is larger at certain positions (such as where wire leading is performed) and smaller at other positions. This localized variation in spacing provides adequate insulation where needed while maintaining a thin overall profile.
Solution Approach 2:
Instead of increasing insulation distance uniformly in the radial direction (which would increase thickness), the patent utilizes the circumferential dimension by varying the distance between coils around the circumference. This allows insulation requirements to be met in specific areas without increasing the overall radial thickness of the coil component.
3Device complexity
If wire leading is performed in area where distance between primary and secondary coil edges is small, then coil structure is compact, but insulation characteristic is deteriorated
Solution Approach 1:
The patent specifically designs the distance between coil edges to be larger at positions where wire leading is performed. This localized increase in spacing provides adequate insulation for wire leading while maintaining compact dimensions at other positions, achieving a balance between compactness and insulation reliability.
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 minimizes leakage flux in upward and downward directions, prevents eddy currents and associated heat/noise, eliminates the need for additional shielding, and enhances insulation and impact resistance while maintaining a thin profile.
Implementation Method 1
a primary coil, which goes around outer circumference of the middle leg, and a secondary coil, which goes around outer circumference of the primary coil
Implementation Method 2
a core including mutually opposing two opposing parts, two side legs mutually connect both ends of the two opposing parts, and a middle leg placed between the two side legs
Data Source
AI summary
The present invention provides a coil component which is possible to be thinner with less leakage flux toward upward and downward directions, and to sustain a good insulation. The coil component comprises a core including two opposing parts mutually opposing, two side legs mutually connect both ends of the two opposing parts, and a middle leg placed between the two side legs and mutually connect central parts of the two opposing parts, a primary coil, which goes around outer circumference of the middle leg, and a secondary coil, which goes around outer circumference of the primary coil, wherein; a distance between outer perimeter edge of the primary coil and inner perimeter edge of the secondary coil varies along circumferential direction.