Dual-Wire Coil Winding Layout for Withstand Voltage Reliability
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Solution Overview
Problem
The existing coil components face degradation in withstand voltage characteristics due to heat-induced deterioration of the wire coating film during thermal crimping, leading to potential current leakage when a potential difference occurs between adjacent wire turns.
Innovation Solution
A coil component design where the first wire and second wire are wound around a non-conductive drum core with specific electrode placements and turn configurations, ensuring a larger potential difference between certain turns and reducing the electric field generated between them, thereby minimizing the risk of coating film deterioration and current leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal crimping is used to connect wires to electrodes, then electrical connection is achieved, but the coating film of the wire deteriorates due to heat influence
Solution Approach 1:
The patent applies preliminary action by positioning the first turn of the second wire away from the first turn of the first wire before the thermal crimping process occurs. This spatial arrangement is established in advance during wire winding, ensuring that when thermal crimping is subsequently applied to connect wires to electrodes, the heat-affected zone does not overlap with adjacent wire turns. The coating film deterioration is prevented because the vulnerable first turn areas are deliberately separated beforehand.
2Area of stationary object
If wires are wound adjacent to each other to increase winding density, then space utilization improves, but electric field concentration increases between adjacent turns
Solution Approach 1:
The patent applies local quality by creating a non-uniform spatial distribution of wire turns. Specifically, the first turn of the second wire is positioned at a greater distance from the first turn of the first wire compared to other adjacent turns. This localized adjustment reduces electric field concentration at the critical interface where thermal crimping occurs, while maintaining normal winding density in other regions. The solution selectively modifies only the necessary local area rather than uniformly spacing all turns.
3Manufacturing precision
If the first turn of the second wire is positioned close to the first turn of the first wire, then manufacturing precision is maintained, but current leakage risk increases due to coating film deterioration and electric field concentration
Solution Approach 1:
The patent applies preliminary anti-action by proactively positioning the first turn of the second wire away from the first turn of the first wire before any deterioration or leakage can occur. This preventive spatial arrangement counteracts the potential harmful effects of heat-induced coating film deterioration and electric field concentration. By establishing this protective distance in advance during the winding process, the design preemptively neutralizes the reliability risks that would otherwise arise from close wire positioning.
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 effectively suppresses the degradation of withstand voltage characteristics by maintaining a reduced electric field between wire turns and preventing coating film deterioration, enhancing the coil component's reliability.
Implementation Method 1
a first wire is wound around the winding core portion and has a first wire end connected to the first electrode and a second wire end connected to the third electrode, and a second wire is wound around the winding core portion
Data Source
AI summary
A coil component includes a drum core including a winding core portion and first and second flange portions, and first and second wires. A portion of the first wire that first comes into contact with an outer peripheral surface of the winding core portion when the first wire is traced from a first wire end to a second wire end is defined as a 1.0 turn portion of the first wire. A portion of the second wire where an angular position thereof about a central axis first coincides with an angular position of the 1.0 turn portion of the first wire, on a side of a second negative direction with respect to the central axis, when the second wire is traced from a first wire end to a second wire end is defined as a 1.0 turn portion of the second wire.