Differential Mode Filter Varying Wire Crossing Angles
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Solution Overview
Problem
Differential mode filters with constant crossing angles between wires suffer from degraded high-frequency characteristics due to capacitance components between the wires and terminal electrodes.
Innovation Solution
A differential mode filter design where the crossing angles between wires are varied, particularly with larger angles at certain crossing portions to reduce capacitance components, while maintaining or reducing core size, and stabilizing wire positions through a quadrangular cross-sectional shape of the winding core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the crossing angle between wires is kept constant, then the structure is simple, but high-frequency characteristics are degraded due to capacitance components between wires and terminal electrodes
Solution Approach 1:
The patent applies local quality by making the crossing angle vary at different positions along the winding core. Specifically, the crossing angle is made larger at crossing portions near the terminal electrodes (first and last crossing portions) compared to intermediate crossing portions. This localized variation reduces capacitance components at critical locations without requiring complex restructuring of the entire wire winding, thus improving high-frequency characteristics while maintaining reasonable structural simplicity.
2Reliability
If the crossing angle between wires is increased at certain portions, then capacitance components are reduced, but the core size may increase
Solution Approach 1:
The patent implements local quality by applying larger crossing angles only at specific critical locations (first and last crossing portions near terminal electrodes) rather than uniformly throughout the entire winding. This localized approach reduces capacitance components where they most affect high-frequency characteristics while minimizing the overall increase in core size, as intermediate crossing portions maintain smaller angles.
Solution Approach 2:
The patent applies partial action by modifying the crossing angle characteristic only at specific portions of the wire winding (the first and last crossing portions) rather than changing the entire winding structure. This partial modification is sufficient to reduce the dominant capacitance components that degrade high-frequency characteristics, without requiring excessive changes that would increase core size.
3Reliability
If wires are wound with varying crossing angles, then capacitance is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by modifying the crossing angle parameter along the length of the winding core. The crossing angle is designed to be larger at the first and last crossing portions and smaller at intermediate portions. This controlled parameter variation reduces capacitance components while the patent also provides guidance on maintaining consistent winding tension and angle to manage manufacturing precision requirements.
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 configuration enhances high-frequency characteristics by minimizing capacitance between wires and terminal electrodes, leading to improved performance without increasing core size, and reduces variations in winding positions.
Implementation Method 1
high-frequency characteristics may be degraded by a capacitance component between the wires and terminal electrodes
Data Source
AI summary
Disclosed herein is a differential mode filter that includes first and second terminal electrodes provided on a first flange part of a core, and first and second wires wound around a winding core part of the core in an opposite direction to each other and connected respectively to the first and second terminal electrodes. The first and second wires cross each other on the winding core part to form a plurality of crossing portions that include first, second, and third crossing portions that are first, second, and third occurrences counting from the one end of the first and second wires, respectively. A first crossing angle between the first and second wires at the first crossing portion is larger than at least one of second and third crossing angles between the first and second wires at the second and third portions, respectively.