Bar Core Coil Winding Collapse Prevention
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Solution Overview
Problem
Existing coil components without a flange part face challenges in downsizing due to winding collapse issues during solenoidal winding, which prevents them from being housed in minute capsules for applications like animal ID tags, and existing solutions like fusion wires or flange parts are either ineffective or increase size.
Innovation Solution
A coil component with a bar-like core and winding part where the conducting wire is wound in layers with a winding collapse preventing shift corresponding to multiple turns between layers, allowing oblique winding to prevent collapse and looseness, enabling dense and stable winding without the need for fusion wires or flange parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a core without flange part is used to downsize the coil component, then the radial size is reduced, but winding collapse occurs at the end part of the winding part
Solution Approach 1:
The patent applies preliminary action by setting a winding collapse preventing shift corresponding to a plurality of turns between the end part of a lower winding layer and the end part of an upper winding layer before the winding process begins. This pre-established shift prevents winding collapse from occurring at the end parts during the solenoidal winding process, while still allowing the core to be without flange parts for downsizing.
2Reliability
If a fusion wire with bonding agent is used to prevent winding collapse, then winding stability is improved, but the bonding agent melts by heat causing deformation and thermal expansion applying stress to the core
Solution Approach 1:
The patent extracts and eliminates the fusion wire with bonding agent from the coil component structure. Instead of using bonding agents that melt and deform under heat, the invention relies on the winding collapse preventing shift design alone to maintain winding stability, thereby avoiding all thermal deformation and stress issues associated with bonding agents.
3Reliability
If a shift corresponding to one turn is applied at the transition from lower layer to upper layer, then a wedge-like space is formed, but this is unrealistic for thin conducting wire and manual winding
Solution Approach 1:
The patent changes the parameter of the shift amount from one turn (as in prior art) to a plurality of turns (winding collapse preventing shift corresponding to multiple turns). This parameter change makes the shift realistic and feasible for thin conducting wires and manual winding processes, while still effectively preventing winding collapse and maintaining winding stability.
Data Source
AI summary
A coil component includes: a bar-like core; and a winding part formed of a conducting wire that is wound in a plurality of layers around the outer periphery of the core according to a solenoidal winding method. Winding collapse preventing shifts D1 to D4 each corresponding to a plurality of turns between an end part of a lower winding layer and an end part of an upper winding layer are respectively set to both end parts in the winding width direction of winding layers of the winding part. In transitioning from the lower winding layer to the upper winding layer, the conducting wire is turned back from the end part of the lower winding layer, and is obliquely wound in a small number of turns across each winding collapse preventing shift corresponding to the plurality of turns, and dense winding of the upper winding layer is started.