Coil Component Winding Structure for Dropout Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Coil components with large wire diameters face issues of wire dropout when wound in multiple layers due to applied forces, leading to increased DC resistance and reduced rated current, as existing technologies struggle to maintain the winding structure without causing upper layer turns to drop to the lower layer.
Innovation Solution
The coil component employs a winding structure where specific turns are wound in an aligned state around the winding core, with subsequent turns supported by at least three wire turns in the lower layer, reducing the likelihood of dropout and minimizing parasitic capacitance by controlling the difference in turn numbers between adjacent turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire with large diameter is used to achieve low DC resistance and high rated current, then electrical performance is improved, but the wire becomes hard to bend and prone to dropout when wound in multiple layers
Solution Approach 1:
The patent applies preliminary action by pre-positioning the (j-th+1) turn along the valley line formed by lower layer turns before completing the upper layer winding. This advance placement ensures proper support structure is established, preventing subsequent wire dropout while maintaining the ability to use large diameter wires for low resistance applications
Solution Approach 2:
The valley line formed by lower layer turns acts as an intermediary support structure. By positioning the (j-th+1) turn along this valley line, the patent creates a stable intermediate position that prevents the wire from dropping to lower layers, thereby enabling the use of large diameter wires without dropout issues
2Length of stationary object
If the wire is wound in multiple layers to increase inductance while suppressing winding core part length, then space efficiency is improved, but wire dropout occurs due to force applied during winding
Solution Approach 1:
The patent establishes the support structure in advance by positioning the (j-th+1) turn along the valley line before completing the upper layer winding. This preliminary positioning prevents wire dropout during the winding process, enabling reliable multi-layer winding on compact cores
Solution Approach 2:
The patent utilizes the vertical dimension by winding in multiple layers rather than extending the winding core length horizontally. The valley line positioning method ensures stability in this multi-layer configuration, allowing compact core design without sacrificing winding integrity
3Reliability
If upper layer turns are supported by multiple lower layer turns, then wire dropout is prevented, but parasitic capacitance increases due to larger difference in turn numbers
Solution Approach 1:
The patent optimizes the parameter of turn number difference by specifically positioning the (j-th+1) turn along the valley line formed by turns (j-th-1) and j-th. This creates a balanced configuration where upper layer turns are supported by at least three lower layer turns, preventing dropout while minimizing the difference in turn numbers to reduce parasitic capacitance
Data Source
AI summary
Disclosed herein is a coil component that includes a winding core part and a wire wound around the winding core part. An i-th turn (i is an integer equal to or larger than 1) to a j-th turn (j is an integer equal to or larger than (i+2)) of the wire are wound in this order around the winding core part in an aligned state. A (j-th+1) turn of the wire is wound around a valley line formed by the i-th turn and a (i-th+1) turn. A (j-th+2) turn of the wire is wound adjacent to the j-th turn around the winding core part.