Flat-Wire Coil Layout for Compact End Routing
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Solution Overview
Problem
Existing coil components with multilayered structures increase in size due to the arrangement of winding wire ends, which complicates manufacturing and assembly.
Innovation Solution
A coil component design featuring a single-layered coil portion with flatwise winding and edgewise bending of flat wire ends to minimize interference and reduce size, allowing for easy mounting and connection of inner and outer coils in parallel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multilayered structure is used to draw out the winding wire ends, then the wiring can be properly arranged, but the coil component increases in size
Solution Approach 1:
The patent transitions from a multilayered vertical arrangement to a single-layer planar arrangement by bending the winding wire ends in the horizontal plane. The first end portion is bent in a first direction and then in a second direction perpendicular to the first direction, while the second end portion is bent in the first direction and then in the second direction opposite to the first, creating a planar configuration that eliminates the need for multiple layers.
2Ease of manufacture
If a multilayered structure is used, then the winding wire ends can be drawn out, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the winding wire end arrangement into distinct functional segments: the first end portion with its first bending portion and first extending portion, and the second end portion with its second bending portion and second extending portion. This segmentation allows each end to be independently configured and connected to corresponding coil ends, simplifying the overall manufacturing process by eliminating the need for complex multilayered structures.
3Reliability
If multiple layers are used to arrange winding wire ends, then proper connection is achieved, but the magnetic path length increases
Solution Approach 1:
The patent merges the winding wire ends and coil ends into a single planar layer, eliminating the separation created by multilayered structures. The first end portion is connected to the first coil end and the second end portion is connected to the second coil end within the same plane, creating a direct magnetic path without the extended routes required by vertical layer transitions.
Data Source
AI summary
A coil component includes a first coil portion formed by flatwise winding of a first flat wire around an axial line extending in a first direction, a first end portion having one end and drawn out from an inner periphery of the first coil portion, and a second end portion having the other end and drawn out from an outer periphery of the first coil portion. The first end portion has a first bending portion formed by edgewise bending of the first flat wire from the inner periphery and extending beyond the first coil portion in the first direction and a first extending portion formed by flatwise bending of the first flat wire from the first bending portion and extending in a second direction intersecting with the first direction.