Common Mode Filter Wire Crossing Stability
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Solution Overview
Problem
The stability of the winding position of wires at the crossing point in common mode filters is unstable, leading to variations in high-frequency characteristics due to the crossing of wires, which affects the performance of these filters in electronic devices.
Innovation Solution
A common mode filter design where the wires are wound in a specific configuration, with the second wire crossing the first wire in a third winding area and being separated from it, ensuring a sufficient crossing angle and reduced contact distance, thereby stabilizing the winding position and enhancing symmetry and high-frequency characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pair of wires are made to cross each other on the way, then symmetry between differential signals in a high-frequency region is enhanced, but the winding position of the upper-side wire becomes unstable at the crossing point
Solution Approach 1:
The patent applies preliminary action by pre-forming the winding core part with a third winding area that has a different surface orientation (radially outward facing) compared to the first and second winding areas. This pre-structured surface configuration guides the wires to naturally cross and separate at predetermined positions before the actual winding process, ensuring stable winding positions at crossing points while maintaining the desired crossing configuration for high-frequency performance.
Solution Approach 2:
The patent applies local quality by creating a specialized third winding area with distinct surface properties (radially outward facing surface) localized at the crossing region. This local structural differentiation provides specific geometric constraints only where needed (at the crossing point), allowing the wires to maintain stable positions during crossing without affecting the winding configuration in other areas, thus resolving the contradiction between crossing stability and high-frequency symmetry.
2Reliability
If wires are separated at least partially in the third winding area, then a sufficient crossing angle is ensured and contact distance is reduced, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing the third winding area to serve multiple functions simultaneously: it provides the crossing geometry for wires, ensures sufficient crossing angle, reduces contact distance, and maintains structural simplicity through a unified radially outward facing surface design. This multi-functional approach achieves the desired wire separation and crossing angle without proportionally increasing device complexity, as the same structural feature accomplishes multiple objectives.
Data Source
AI summary
Disclosed herein is a common mode filter that includes a winding core part including a first winding area positioned at one end side in an axial direction, a second winding area positioned at other end side in the axial direction, and a third winding area positioned between the first and second winding areas; and first and second wires wound in a same direction around the winding core part. The first wire is aligned and wound in the first and second winding areas, and the second wire is wound on the first wire in the first and second winding areas. The first and second wires cross each other in the third winding area and are separated at least partially in the third winding area.