Dual-Wire Coil Winding Layout to Prevent Turn-to-Turn Slippage
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Solution Overview
Problem
Existing coil components face issues with orderly winding due to the second wire falling between turns of the first wire, leading to deviations from the designed specifications, as the pressing force causes the second wire to shift and lose contact with the intended position.
Innovation Solution
A coil component design featuring a drum core with a winding core shaped like a column or prism, where the second wire is wound to intersect the first wire twice within a specific turn, ensuring it contacts the first wire from both sides, preventing easy movement along the central axis and maintaining the intended winding configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second wire is wound around the winding core and pressed against the first wire, then the second wire should stay on the outward-facing part of the first wire, but the pressing force causes the second wire to fall in between adjacent turns of the first wire
Solution Approach 1:
The patent introduces a new spatial dimension by having the second wire intersect the first wire at two distinct points within a single turn, rather than simply wrapping around it. This dual-intersection configuration creates a topologically stable structure where the second wire is mechanically locked by crossing over and under the first wire multiple times, preventing it from falling between turns despite pressing forces.
2Manufacturing precision
If the second wire is pressed against the first wire during winding, then contact between the wires is ensured, but the second wire moves and loses contact with the intended position
Solution Approach 1:
The patent applies preliminary anti-action by pre-configuring the second wire to intersect the first wire at two points before the pressing force is fully applied. This pre-established dual-intersection geometry creates inherent mechanical resistance to the pressing force, preventing the second wire from displacing and losing its intended position during the winding process.
3Reliability
If the second wire is wound to intersect the first wire twice within a specific turn, then the second wire is securely positioned and cannot move easily, but the winding process becomes more complex
Solution Approach 1:
The patent implements self-service by designing the winding process where the second wire's own geometry and positioning automatically create the dual-intersection configuration. The wire's path is configured to naturally cross the first wire at two points through its own winding pattern, eliminating the need for external fixtures, guides, or complex positioning mechanisms to achieve the intersecting configuration.
Data Source
AI summary
A coil component includes a drum core, a first wire, and a second wire. The drum core includes a winding core, a first flange, and a second flange. The first wire includes a first winding portion. The second wire includes a second winding portion. When the second wire is traced from the end at the first flange toward the second flange, a specific position is a position at which the second wire comes into first contact with an outward-facing part of the first wire, and a specific turn is a turn of the second wire that is wound around from the specific position so as to proceed toward the second flange. The second winding portion has, within the specific turn, two intersections at which the second wire intersects the first wire.