Dual-Wire Coil Winding Layout for Higher Withstand Voltage
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Solution Overview
Problem
The existing coil components suffer from degradation of withstand voltage characteristics due to potential differences and electric fields generated between adjacent turns of wires, which can lead to current leakage and insulation film deterioration, particularly when wires are thermally crimped to electrodes.
Innovation Solution
The coil component design includes a winding core with specific electrode placements and wire winding directions such that the 1.0 turn portions of the first and second wires are positioned away from each other, reducing the electric field and potential differences, thereby minimizing insulation film deterioration and enhancing withstand voltage characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are thermally crimped onto electrodes, then electrical connection is achieved, but coating film deterioration occurs due to heat influence
Solution Approach 1:
The patent extracts the harmful thermal effect from the connection process by separating the thermal crimping operation from the wire sections that require insulation integrity. Specifically, the design ensures that the 1.0 turn portions (which are most susceptible to heat damage) are positioned away from the electrode connection points, thereby removing the direct thermal exposure from the critical insulation regions.
Solution Approach 2:
The patent applies dimensional reasoning by considering the spatial arrangement of wire turns along the axial direction. By positioning the 1.0 turn portions at specific axial locations away from the electrode interfaces, the design uses the axial dimension to separate the thermal hazard zone from the insulation-critical zones, thereby resolving the contradiction between achieving electrical connection and preserving coating integrity.
2Quantity of substance
If 1.0 turn portions of adjacent wires are positioned close to each other, then winding density is increased, but electric field intensity increases causing current leakage
Solution Approach 1:
The patent introduces asymmetry in the positioning of 1.0 turn portions between adjacent wires. Instead of symmetric placement that would maximize winding density, the design deliberately creates asymmetric spacing where the 1.0 turn portions of adjacent wires are offset from each other along the axial direction. This asymmetric arrangement reduces the electric field intensity between adjacent turns while maintaining acceptable winding density.
Solution Approach 2:
The patent applies local quality by creating different spatial relationships at different locations along the wire length. Specifically, the 1.0 turn portions are positioned with increased spacing relative to each other, while other portions of the wires maintain close proximity for efficient winding. This localized differentiation allows the design to reduce electric field intensity at critical points without compromising overall winding density.
3Power
If potential difference occurs between adjacent wires, then electromagnetic coupling is enhanced, but withstand voltage characteristics degrade due to current leakage
Solution Approach 1:
The patent introduces the spatial positioning of 1.0 turn portions as an intermediary element that mediates between electromagnetic coupling and withstand voltage characteristics. By controlling the axial position of these turns away from high electric field regions, the design allows electromagnetic coupling to be maintained through proper winding geometry while preventing current leakage that would degrade withstand voltage performance.
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 reducing electric fields between wire turns, ensuring reliable operation and improved impedance characteristics, especially in high-frequency regions.
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
Implementation Method 2
A first wire end of the first wire is thermally crimped onto the first electrode. A second wire end of the first wire is thermally crimped onto the third electrode.
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.