Coil Insulation Layout for Shorter Axial Length
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Solution Overview
Problem
Existing coils face challenges in size reduction due to insulation coating films, which hinder the shortening of coil length along the axis, leading to degraded performance when the number of turns is reduced.
Innovation Solution
A coil design with a spirally wound conductor wire and an insulator that differentiates between insulation thicknesses, allowing for thinner insulation in non-essential areas, reducing the overall coil length and maintaining performance by minimizing unnecessary insulation film thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation coating film covers the entire copper plate of the flat conductor wire, then insulation reliability is improved, but the coil thickness increases and size reduction is hindered
Solution Approach 1:
The patent applies local quality by differentiating insulation thickness across different regions of the coil. The insulation coating is made thinner at the end surfaces (first and second ends) while maintaining sufficient thickness in the intermediate portions between adjacent turns. This localized variation in insulation quality reduces overall coil thickness while preserving insulation reliability where it is most critical - between adjacent windings.
2Length of stationary object
If the number of turns of the coil is reduced to shorten the coil length, then coil size is reduced, but coil performance is degraded
Solution Approach 1:
The patent changes the insulation thickness parameter selectively across different coil regions. By reducing insulation thickness at end surfaces while maintaining it in intermediate regions, the overall coil length and thickness are reduced without compromising the electrical insulation performance that would be required for maintaining inductance and preventing short circuits between turns.
3Ease of manufacture
If uniform insulation thickness is maintained throughout the coil, then manufacturing simplicity is improved, but coil thickness increases and integration into compact devices becomes difficult
Solution Approach 1:
The patent implements local quality by applying different insulation thicknesses to different portions of the coil. The intermediate portions between adjacent turns maintain sufficient insulation thickness for electrical reliability, while the end surfaces have reduced insulation thickness. This approach achieves compact coil dimensions suitable for modern electronics while remaining compatible with standard insulation coating processes.
Data Source
AI summary
A coil that includes: a coil wire spirally wound along an axis; and an insulator that covers at least a portion of the coil wire. In a cross section including the axis, the insulator includes: a first insulation portion in contact with a first end surface of the coil wire on a first side in a direction of the axis of the coil wire, a second insulation portion in contact with a second end surface of the coil wire on a second side in the direction of the axis of the coil wire, and a third insulation portion between adjacent turns in the direction of the axis of the coil wire. At least one of a first thickness of the first insulation portion and a second thickness of the second insulation portion is thinner than half of a third thickness of the third insulation portion.