Coil Device Low Profile with Integrated Lead Grooves
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Solution Overview
Problem
Existing coil devices for resonance transformers, such as those used in liquid crystal display backlights, face challenges in achieving a low height profile while preventing leakage flux that causes eddy currents and heat/noise issues, and struggle with automating the connection of secondary coil leads to terminals.
Innovation Solution
A coil device design featuring a bobbin with a primary coil wound on a hollow cylinder and a case with a secondary coil wound on the outer circumference, where the secondary coil's lower collar extends to the bobbin plate, incorporating grooves for lead wires to facilitate easy connection and insulation, reducing the need for terminals on the case and allowing for a more economical and flexible design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the secondary coil is wound on the outer circumference of the primary coil to achieve low height profile, then the height of the coil device is reduced, but it becomes difficult to automate the connection of lead wires to terminals
Solution Approach 1:
The patent introduces an intermediary structure (the extended lower collar part with integrated grooves) that mediates between the compact coil structure and the lead wire connection requirement. This intermediary element provides both mechanical support and guided pathways for lead wires, enabling automated connection processes while maintaining the low-height design.
Solution Approach 2:
The lower collar part of the case serves multiple functions: it provides structural support, guides lead wires through integrated grooves, and extends to the bobbin plate to facilitate connections. This multi-functionality reduces the need for separate components and simplifies the automated connection process.
2Object-affected harmful factors
If aluminum board is implemented on upward and downward directions to prevent leakage flux, then leakage flux is reduced, but heat dissipation of the coil is deteriorated
Solution Approach 1:
The patent extracts the harmful leakage flux by introducing magnetic shielding plates made of magnetic material. These plates are strategically positioned to capture and redirect leakage flux away from constructional materials, eliminating the need for aluminum boards that would block heat dissipation.
Solution Approach 2:
The patent changes the material parameter from non-magnetic aluminum board to magnetic shielding material, which has different magnetic properties. This parameter change allows the shielding to work through magnetic field interaction rather than physical blocking, preserving thermal conduction pathways.
3Ease of operation
If the lower collar part is extended to the bobbin plate with grooves for leads, then the connection process is simplified and automation is enabled, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the lower collar part: structural support, lead wire guidance through grooves, and extension to the bobbin plate. By combining these functions into a single integrated component, the overall device complexity is reduced compared to using separate elements for each function.
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 achieves a low height profile, simplifies the connection process for lead wires, maintains insulation, and reduces production costs while minimizing heat dissipation issues and noise associated with eddy currents.
Implementation Method 1
a resonance transformer is used to obtain a high-voltage
Implementation Method 2
a leakage flux from the coil device causes eddy current in constructional material and the like, and then heat or noise associated with said occurrence of eddy current are caused
Data Source
AI summary
A coil device 10 comprises a bobbin 40 having a bobbin plate 42 provided with a first hollow cylinder 44 on which a primary coil 20 is wound, and a case 50 provided with a second hollow cylinder 54 wound by a secondary coil 30 at the outer circumference. On the bobbin plate 42, a primary terminal 70 connecting to the primary coil 20 and a secondary terminal 72 connecting to the secondary coil 30 are formed, and a tip end portion 55a of case 50 is extended to the end portion of the bobbin plate 42 to which the secondary terminal 72 is formed. Further, on the tip end portion 55a, plural first grooves 57a for lead are formed.