Coil Device Partition Walls Insulation
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Solution Overview
Problem
Conventional coil devices face issues with voltage withstandability, high-frequency characteristics, and stability of leakage characteristics due to regular winding methods, which lead to voltage differences and interference between adjacent wires, and instability in leakage flux.
Innovation Solution
A coil device design featuring partition walls and connecting grooves on bobbins to separate and insulate adjacent wires, allowing for controlled winding and improved voltage withstandability and high-frequency performance, while maintaining stability of leakage characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If regular winding method is used for secondary coil, then manufacturing is simple, but voltage withstandability deteriorates due to voltage differences between adjacent wires
Solution Approach 1:
The coil winding is segmented into multiple independent layers using partition walls. Each layer is wound separately around its own bobbin, preventing direct contact between adjacent wires of different layers. This segmentation eliminates the voltage difference problem while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
Partition walls act as intermediary insulating structures between adjacent wire layers. These partition walls physically separate the wires, preventing direct electrical contact and eliminating the harmful voltage differences that occur in regular winding methods.
2Volume of moving object
If wires are closely wound in regular winding, then space utilization is high, but high-frequency characteristics deteriorate due to interference between adjacent wires
Solution Approach 1:
The winding structure is divided into separate layers by partition walls, allowing each layer to be optimally packed without interfering with adjacent layers. This segmentation maintains high space utilization while eliminating the electromagnetic interference that occurs when wires are closely wound together in regular winding.
3Device complexity
If conventional coil device is used, then structure is simple, but leakage characteristics are unstable due to wire positioning variations
Solution Approach 1:
Partition walls are pre-formed on the bobbins before winding begins. This preliminary action establishes fixed, predetermined positions for each wire layer, ensuring consistent wire placement and spacing throughout the winding process. The result is stable leakage characteristics while adding minimal structural complexity.
Solution Approach 2:
The invention changes the positional parameters of wires by introducing partition walls at specific intervals. This creates fixed geometric relationships between adjacent wires, transforming the variable wire positions in conventional windings into controlled, repeatable positions that ensure stable leakage characteristics.
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
The design enhances voltage withstandability, high-frequency characteristics, and leakage stability by insulating adjacent wires and controlling the coupling coefficient between primary and secondary coils, allowing for efficient use in leakage transformers with improved heat dissipation and reduced leakage flux.
Implementation Method 1
portions of the wire which are adjacent to each other in a direction of the scroll axis are insulated by partition walls
Implementation Method 2
a first winding part at an outer circumference to which a first wire composing either a primary coil or a secondary coil is wound
Data Source
AI summary
A coil device 10 comprises a first bobbin 40 provided with a first winding part 45 at an outer circumference and a second bobbin 50 provided with a second winding part 55 at an outer circumference. A plurality of partition walls 46, separating portions of the wire 22 which are adjacent to each other along the scroll axis Z of the first wire 22 are formed on the first winding part 45 along the scroll axis at predetermined intervals. A section width w1 of each section 47, which is along the scroll axis Z, separated by the partition walls 46 is determined so that only one wire 22 can pass through. A height of the partition walls 46 is determined so that one or more of the wires 22 can pass through. At least one connecting groove 46a, connecting each section which are adjacent to each other, is formed on each partition wall 46.