Coil Component Gathering Member for High Current Compact Transformers
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Solution Overview
Problem
Transformers face challenges in adapting to large currents without increasing size, as thickening winding wires can cause short circuits and increased size, respectively.
Innovation Solution
A coil component with a gathering member that collects the terminal ends of multiple winding wires, allowing for parallel connection without thickening, thereby managing high currents while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire diameter of secondary-side winding wire is increased to adapt to large current, then the current carrying capacity is improved, but the secured point thickens and causes short circuit with adjacent terminal
Solution Approach 1:
The patent introduces a gathering member that extends in the thickness direction (third dimension) to collect and separate terminal ends of multiple winding wires. This dimensional approach allows thick wires to be secured without lateral expansion that would cause short circuits, as the gathering member provides vertical separation and organization of the secured points.
2Reliability
If the wire diameter of secondary-side winding wire is increased to adapt to large current, then the current carrying capacity is improved, but the transformer increases in size
Solution Approach 1:
By utilizing the thickness direction for wire gathering and organization, the patent allows efficient current distribution through multiple wires without increasing the planar footprint. The gathering member enables vertical stacking and compact arrangement of thick winding wires, maintaining small transformer size while achieving high current carrying capacity.
3Reliability
If multiple winding wires are connected in parallel to adapt to large current, then the current carrying capacity is improved, but the winding wires may fall apart and come into contact causing short circuit
Solution Approach 1:
The gathering member merges and consolidates multiple separate winding wires into a single organized bundle at the terminal end. This combining approach maintains the parallel connection benefits for current distribution while providing unified structural support that prevents individual wires from falling apart or making unintended contact.
Solution Approach 2:
The gathering member acts as an intermediary component between the multiple winding wires and the terminal. It provides a mediating structure that holds the wires in proper alignment and separation, preventing direct contact between adjacent wires while facilitating their collective connection to the terminal for high current capability.
4Object-affected harmful factors
If the interval between terminals is increased to avoid short circuit, then the short circuit risk is reduced, but the transformer increases in size
Solution Approach 1:
Instead of increasing horizontal interval between terminals to prevent short circuits, the patent uses the thickness direction to provide separation and organization. The gathering member collects terminal ends and positions them vertically, allowing terminals to remain closely spaced in the planar view while maintaining adequate separation through the third dimension, thus preventing short circuits without increasing transformer footprint.
Data Source
AI summary
A coil component including a terminal for external connection to which a plurality of secondary-side winding wires are connected, and a gathering member that gathers vicinities of terminal ends of the plurality of winding wires.