Overlapping Coil Conductor Layout With Insulated Magnetic Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil devices face challenges in sufficiently increasing magnetic coupling between conductors due to their configuration, leading to difficulties in achieving high reliability and preventing short-circuit failures.
Innovation Solution
The coil device incorporates an insulating layer between conductors and a core structure that allows for efficient magnetic flux transmission while maintaining insulation, using conductors with overlapping arrangements and insulating films or resin spacers to prevent short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are disposed close to each other to increase magnetic coupling, then magnetic coupling is improved, but short-circuit risk increases
Solution Approach 1:
An insulating layer is introduced as an intermediary between the first and second conductors. This insulating layer physically separates the conductors to prevent short-circuit while maintaining close proximity for efficient magnetic coupling. The insulating layer acts as a mediator that resolves the contradiction between needing close spacing for magnetic coupling and requiring separation for electrical isolation.
2Reliability
If an insulating layer is added between conductors to prevent short-circuit, then reliability is improved, but device complexity increases
Solution Approach 1:
The insulating layer is implemented as a thin film structure that covers the conductors. This thin film approach provides effective electrical insulation without adding significant structural complexity or volume. The flexible thin film nature of the insulating layer allows it to conform to the conductor geometry, simplifying the overall device structure while maintaining reliability.
3Reliability
If conductors are arranged in overlapping configuration to improve magnetic coupling, then magnetic flux transmission is improved, but manufacturing precision requirements increase
Solution Approach 1:
The insulating layer is applied to the conductors before the overlapping arrangement is finalized. This preliminary action of insulating the conductors allows for easier handling and positioning during assembly, reducing the precision requirements for the overlapping configuration. The pre-applied insulating layer acts as a protective and positioning aid during the manufacturing process.
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 enhances magnetic coupling and ensures high reliability by preventing short-circuit failures, allowing for stable connections to mounting surfaces and efficient heat dissipation.
Implementation Method 1
an insulating layer is formed at least between the first conductor and the second conductor
Implementation Method 2
the magnetic flux can efficiently be transmitted between the first conductor and the second conductor, and the magnetic coupling between the first conductor and the second conductor can be increased sufficiently
Data Source
AI summary
A coil device includes a first conductor, a second conductor, and a core. The second conductor is disposed inside the first conductor and at least partly extending along the first conductor. The core internally arranges the first conductor and the second conductor. An insulating layer is formed at least between the first conductor and the second conductor.