Drum-Core Coil Winding With Symmetric Twisted Wire Geometry
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Solution Overview
Problem
Wire-wound common mode choke coils with polygonal cross sections experience winding irregularities due to twisted wire states, leading to uneven quality and stability issues.
Innovation Solution
A coil component with a drum-shaped core and wires twisted in identical shapes on parallel surfaces, ensuring a stable wound state by aligning wires horizontally at ridge parts and using a specific winding method to maintain consistent twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are wound around a core with polygonal cross section, then the coil component can be manufactured with standard winding processes, but winding irregularities occur causing uneven quality and stability issues
Solution Approach 1:
The patent applies asymmetry by making the first and second twisted wire parts have different configurations. Specifically, the first twisted wire part has wires twisted in a first direction while the second twisted wire part has wires twisted in a second direction opposite to the first direction. This asymmetric twisting arrangement compensates for the geometric irregularities caused by the polygonal core cross-section, ensuring that wires maintain consistent contact and twisted states across all winding positions, thereby resolving the wound state instability issue.
2Stability of the object's composition
If wires are twisted together to maintain stable wound state, then winding irregularities are reduced, but the complexity of maintaining identical twisted shapes on parallel surfaces increases
Solution Approach 1:
The patent applies periodic action by creating a repeating pattern of twisted wire parts around the core. The first twisted wire part and second twisted wire part are arranged periodically around the circumferential surface of the core, with each having identical shapes but twisted in opposite directions. This periodic arrangement ensures that the stabilizing effect is distributed uniformly around the core, maintaining consistent wound states throughout the coil structure while following a systematic, repeatable pattern that manages complexity.
Data Source
AI summary
A coil component includes a drum-shaped core including a core part having a circumferential surface including a first side surface and a second side surface parallel to each other; and a coil including two wires wound around the core part in the same direction. The coil has a first twisted wire part having the two wires twisted together on the first side surface, and a second twisted wire part having the two wires twisted together on the second side surface. The first twisted wire part and the second twisted wire part are identical in shape.