Polygonal Inductor Core Corners for Stable Thick-Wire Winding
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Solution Overview
Problem
Existing wire wound inductor components face instability in multi-layer winding, particularly with thick wires, due to difficulty in maintaining the returning point's position on the winding core, leading to unstable positioning and slipping issues in bank winding configurations.
Innovation Solution
A winding core with a polygonal cross-section having corner portions with 90-degree to 120-degree interior angles and adjacent round surfaces that protrude outward, increasing friction and stabilizing the wire's position, along with a manufacturing method using ceramic powder and punches to form the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a winding core portion has a circular or elliptical cross section, then thick wires can be wound stably around the entire circumferential surface, but the returning point of the wire cannot be positioned stably in multi-layer winding
Solution Approach 1:
The invention applies local quality by providing round surfaces only at specific corner portions of the winding core, rather than making the entire cross-section circular. This localized rounding at corner portions with 90-120 degree interior angles provides stable positioning for thick wires during bank winding, while maintaining the polygonal cross-section structure needed for multi-layer winding stability.
2Manufacturing precision
If a winding core portion has a quadrangular or hexagonal cross section, then the returning point can be positioned stably, but thick wires slip in the axial direction due to reduced friction
Solution Approach 1:
The invention applies local quality by providing round surfaces only at specific corner portions of the winding core, rather than making the entire cross-section circular. This localized rounding at corner portions with 90-120 degree interior angles provides stable positioning for thick wires during bank winding, while maintaining the polygonal cross-section structure needed for multi-layer winding stability.
3Ease of manufacture
If corner portions have sharp edges to maintain polygonal shape, then manufacturing is simpler, but friction between wire and core is reduced causing wire slippage
Solution Approach 1:
The invention applies local quality by providing round surfaces only at specific corner portions of the winding core, rather than making the entire cross-section circular. This localized rounding at corner portions with 90-120 degree interior angles provides stable positioning for thick wires during bank winding, while maintaining the polygonal cross-section structure needed for multi-layer winding stability.
Solution Approach 2:
The invention applies spheroidality by forming round surfaces at the corner portions of the winding core. These rounded corners increase the friction between the thick wire and the core, preventing wire slippage in the axial direction during bank winding, while the overall polygonal cross-section is maintained.
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
The solution enables stable winding of thick wires by increasing friction at corner portions, maintaining the wire's position and preventing slipping, thus ensuring consistent multi-layer winding patterns.
Implementation Method 1
the wire comes into contact with the entire circumferential surface of the winding core portion, and accordingly the wire can be wound around stably
Data Source
AI summary
A winding core portion includes corner portions. The cross section of the winding core portion taken in a direction orthogonally intersecting the longitudinal axis thereof is a polygon having four corners or more. The interior angle of each corner between adjacent sides of the polygon is 90 degrees or more and less than 120 degrees (i.e., from 90 degrees to 120 degrees) on the cross section. At least one of the corner portions has a first round surface and a second round surface that are formed so as to protrude outward and are arranged adjacently to each other in a circumferential direction of the winding core portion.