Double Coil Layout for Higher Magnetic Coupling Coefficient
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Solution Overview
Problem
Conventional coil components face difficulties in achieving a high coupling coefficient in double coil configurations.
Innovation Solution
The coil component design includes a pair of coil portions with planar coil patterns and through conductors on opposite surfaces of an insulating substrate, where the coil patterns are wound around a magnetic core with equal distances from the end surfaces and connected by through conductors, enhancing magnetic coupling and allowing for different inductance values by varying the number of turns in each coil portion, while maintaining line symmetry for simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double coil is formed by conventional planar coil patterns on substrate surfaces, then the structure is simple to manufacture, but the coupling coefficient between coils is low
Solution Approach 1:
The patent transitions from conventional planar coil patterns on substrate surfaces to three-dimensional coil structures formed by winding conductors around a magnetic core. This dimensional change enables magnetic fields to penetrate through the core, significantly enhancing the coupling coefficient between primary and secondary coils while maintaining manufacturability through automated winding processes
Solution Approach 2:
The patent employs a composite structure combining a magnetic core material with wound conductor windings. The magnetic core provides high permeability to concentrate and guide magnetic flux, while the conductive windings carry current to generate and receive magnetic fields. This composite arrangement optimizes both magnetic coupling and electrical performance
2Adaptability or versatility
If coil patterns are made with equal distances from end surfaces, then manufacturing is simplified, but the ability to achieve different inductance values is limited
Solution Approach 1:
The patent enables dynamic adjustment of inductance values by varying the number of turns in coil windings while maintaining a fixed symmetric core structure. The core provides a consistent magnetic path, while the flexible winding count allows customization of inductance for different application requirements without changing the fundamental manufacturing process
Solution Approach 2:
The patent segments the coil structure into a standardized magnetic core portion and variable winding portions. The core maintains fixed symmetric geometry for manufacturing simplicity, while the windings can be independently adjusted in number and configuration to achieve different inductance values, separating the manufacturing template from the customization parameter
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 design achieves a high coupling coefficient between the coil portions, allows for different inductance values, and simplifies the manufacturing process by ensuring line symmetry and accurate formation of planar coil patterns.
Implementation Method 1
magnetic coupling is enhanced at locations (that is, the first through conductor and the second through conductor) at which the planar coil patterns on one surface of the insulating substrate and the planar coil patterns on the other surface of the insulating substrate are connected
Data Source
AI summary
In a coil component, a double coil is configured of a first coil portion and a second coil portion, and a first through conductor of the first coil portion and a second through conductor of the second coil portion are adjacent to each other. Thus, the first coil portion and the second coil portion have enhanced magnetic coupling at locations (that is, the first through conductor and the second through conductor) at which planar coil patterns of upper and lower surfaces of an insulating substrate are connected, in addition to magnetic coupling in the planar coil patterns wound around a through hole. Therefore, according to the coil component, a high coupling coefficient between the first coil portion and the second coil portion is realized.