Multi-Layer Coil Component Winding for Miniaturization
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Solution Overview
Problem
The challenge is to reduce the size of coil components while maintaining desired inductance values, as existing methods result in increased drum core size and winding region dimensions, making it difficult to achieve smaller coil components.
Innovation Solution
A method for manufacturing coil components involves winding a first conductive wire around a drum core in a single layer, followed by winding a second conductive wire on the outer periphery of the first wire, with specific positioning to minimize axial spacing and flange part requirements, allowing for reduced component size without increasing the flange or core dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductive wires are wound around a winding core in a single layer from one flange to the other, then desired inductance values can be obtained, but the winding region becomes larger and the drum core size increases
Solution Approach 1:
The patent transitions from a single-layer winding configuration to a multi-layer winding configuration, where conductive wires are wound in multiple layers around the winding core. This dimensional change allows achieving desired inductance values without increasing the axial length of the drum core, as the additional winding layers are arranged radially rather than axially.
Solution Approach 2:
The patent implements nested winding where conductive wires are wound in multiple concentric layers around the winding core. Each layer is nested within the radial space of the drum core, allowing multiple turns to be accommodated without increasing the axial dimension, thus reducing the overall drum core size while maintaining required inductance.
2Reliability
If the winding region is increased to accommodate multiple turns, then desired inductance can be achieved, but the coil component size increases
Solution Approach 1:
The patent utilizes the radial dimension of the drum core to accommodate multiple winding layers, rather than extending the winding region axially. This allows achieving higher inductance values by increasing the number of turns through radial nesting instead of axial extension, thereby reducing the winding region area.
3Volume of moving object
If the drum core size is reduced for miniaturization, then coil component size is reduced, but it becomes difficult to wind multiple conductive wires by the same number of turns
Solution Approach 1:
The patent employs nested multi-layer winding where conductive wires are arranged in concentric layers around the winding core. This nesting approach allows multiple turns to be accommodated within a compact radial space, enabling miniaturization of the drum core while maintaining the ability to wind conductive wires by the same number of turns for consistent inductance values.
Solution Approach 2:
The patent changes the winding configuration parameters from single-layer to multi-layer arrangement, allowing the same number of turns to be achieved in a more compact volume. This parameter change enables reduction of drum core size while maintaining inductance requirements through optimized spatial arrangement of conductive wires.
Data Source
AI summary
A method for manufacturing a coil component includes: a first winding step to wind a first conductive wire around a winding core in a single layer from a first flange part toward a second flange part; and a second winding step to wind a second conductive wire around the winding core on the first conductive wire by the same number of turns and in the same direction as in the first winding step in a single layer in a manner that center B of the cross-section of the second conductive wire closest to the first flange part is positioned closer to the first flange part than is center A of the cross-section of the first conductive wire closest to the first flange part, and that the distance in the axial direction, between centers A and B is smaller than the radius of the wire.