Flat-Wire Coil Geometry to Prevent Turn Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components with flat wire windings face issues of turns moving out of alignment due to stress release or residual stress, leading to potential loosening during manufacturing and operation.
Innovation Solution
The coil component design includes a magnetic base body with a coil part featuring turns that have inwardly protruding and depressed peripheral surfaces, connected by curved surfaces, to maintain alignment and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat wire is wound to form a coil part, then the coil part can be manufactured using widely available flat wire, but the turns tend to move out of alignment in the axial direction due to spring back effect and residual stress
Solution Approach 1:
The patent applies curvature by forming the peripheral surfaces of the turns into depressed or protruding curved shapes rather than flat surfaces. This curvature creates mechanical interlocking between adjacent turns, preventing them from moving out of alignment in the axial direction while maintaining manufacturability with standard flat wire winding processes.
2Stability of the object's composition
If the turns are aligned on the winding plane, then the coil part maintains proper geometry, but stress release and spring back effect cause the turns to move out of alignment
Solution Approach 1:
The curved peripheral surfaces (depressed or protruding) provide mechanical interlocking between turns, creating a stable configuration that resists displacement from stress release and spring back effects, thereby maintaining alignment stability and structural reliability simultaneously.
Solution Approach 2:
The patent introduces asymmetry in the turn geometry with non-uniform peripheral surfaces that have different profiles at different locations. This asymmetric design creates directional constraints that prevent axial movement while allowing proper winding, resolving the conflict between alignment stability and structural reliability.
3Manufacturing precision
If the turns are prevented from moving by adding constraints, then alignment is maintained, but the device complexity increases
Solution Approach 1:
The patent merges the alignment constraint function into the turn geometry itself through the curved peripheral surfaces. Instead of adding separate constraint mechanisms, the constraining feature is integrated directly into the winding structure, maintaining alignment precision without increasing device complexity.
Solution Approach 2:
The curved peripheral surfaces of the turns self-constrain adjacent turns through mechanical interlocking. The structure serves its own alignment function without requiring external constraints or additional components, thereby maintaining precision while minimizing complexity.
Data Source
AI summary
A coil component includes a coil part. The coil part includes a first turn part extending around a coil axis running in an axial direction, a second turn part outside the first turn part in a radial direction orthogonal to the axial direction and centered on the coil axis, and an insulating coating film covering a surface of the coil part. The first turn part has first inner and outer peripheral surfaces facing each other, and the first outer peripheral surface is depressed inwardly in the radial direction when seen in a section of the coil component along a plane passing through the coil axis, and the second turn part has second inner and outer peripheral surfaces facing each other, and the second inner peripheral surface faces the first outer peripheral surface and protrudes inwardly in the radial direction when seen in the section.