Copper Coil Form for Inductive Element Power Density
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Solution Overview
Problem
Current inductive elements face limitations in achieving high power density due to reduced copper fill factors and increased losses caused by plastic coil formers, which restrict their application in high-power, high-current applications.
Innovation Solution
A coil form made entirely of electrically conducting material, such as copper, is used as the winding for the inductive element, enhancing copper fill factor, reducing losses, and improving magnetic coupling, while allowing for easier recycling and reduced use of hazardous substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic coil formers are used to provide insulation distances, then safety requirements are met, but copper fill factor is reduced and losses increase
Solution Approach 1:
The coil form material is changed from plastic to electrically conducting material, fundamentally altering the electrical parameters of the system. This allows the coil form to become part of the electrical circuit, transforming it from an insulating component to a conductive component that actively participates in current flow and magnetic field generation.
Solution Approach 2:
The coil form is merged with the winding structure by using the same electrically conducting material for both. The coil form itself becomes a winding of the second coil, eliminating the distinction between structural support and electrical conductor, thereby maximizing copper fill factor and reducing energy losses.
2Reliability
If plastic coil formers are used to provide insulation distances, then safety requirements are met, but copper fill factor is reduced
Solution Approach 1:
The coil form material is changed from plastic to electrically conducting material, fundamentally altering the electrical parameters of the system. This allows the coil form to become part of the electrical circuit, transforming it from an insulating component to a conductive component that actively participates in current flow and magnetic field generation.
Solution Approach 2:
The coil form is merged with the winding structure by using the same electrically conducting material for both. The coil form itself becomes a winding of the second coil, eliminating the distinction between structural support and electrical conductor, thereby maximizing copper fill factor and reducing energy losses.
3Reliability
If plastic coil formers are used, then insulation is provided, but thermal dissipation is reduced
Solution Approach 1:
The coil form material is changed from plastic to electrically conducting material, fundamentally altering the electrical parameters of the system. This allows the coil form to become part of the electrical circuit, transforming it from an insulating component to a conductive component that actively participates in current flow and magnetic field generation.
Solution Approach 2:
The invention uses composite construction with the coil form made of electrically conducting material (such as copper) that provides both structural support and electrical conduction. The flange portions and mantle portion are integrally formed or securely connected to create a unified structure that optimizes both mechanical and thermal properties.
4Power
If multiple PCB's are paralleled to carry high currents, then current capacity is increased, but insulation space increases and copper fill factor decreases
Solution Approach 1:
The invention transitions from planar PCB traces to three-dimensional wound coil structures. By winding the conducting material around the coil form in multiple turns, high current capacity is achieved in a compact volumetric arrangement rather than requiring multiple stacked PCB layers, thereby maximizing copper fill factor in the available space.
Solution Approach 2:
The coil form is merged with the winding structure by using the same electrically conducting material for both. The coil form itself becomes a winding of the second coil, eliminating the distinction between structural support and electrical conductor, thereby maximizing copper fill factor and reducing energy losses.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in higher power density, reduced manufacturing costs, and improved thermal dissipation, making it suitable for high-power applications with enhanced electrical and magnetic characteristics.
Implementation Method 1
the electrically conducting material typically conducts heat better than a coil form made of plastic
Implementation Method 2
enhanced magnetic coupling and therefore in an increased power density of the inductive element
Data Source
AI summary
The coil form according to the invention for forming an inductive element includes a hollow cylindrical mantle portion, two flange portions and a slit. The flange portions and the mantle portion form a winding chamber for winding therein a wire that forms a first winding or a part of a first winding of the inductive element. The coil form, which is completely made of copper, forms a second coil or a winding of a second coil of the inductive element. Due to the increased contact surface between the first and the second coil the heat dissipation capabilities and the magnetic coupling between the coils are increased. This in turn results in an increased power density of the inductive element.