Inductor Winding Configuration for Shape Stability
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Solution Overview
Problem
Inductors in mobile communication devices face challenges in maintaining shape stability and reducing winding layer thickness, particularly in the return winding portion, leading to variations in inductance values and potential wire breakage.
Innovation Solution
The inductor design features a winding wire configuration with a forward winding layer, a backward winding layer, and a return winding portion that passes over the backward winding layer within less than ½ turn to reach the winding core, stabilizing the return winding portion and reducing the number of turns, thereby minimizing variations in inductance and preventing wire protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the winding wire is wound in multiple layers around the winding core portion to reduce inductor size, then the inductor volume is reduced, but the winding layer thickness increases and shape stability deteriorates
Solution Approach 1:
The winding wire is divided into distinct functional segments: forward winding layer, backward winding layer, and return winding portion. This segmentation allows each part to perform its specific function optimally, with the return winding portion specifically designed to maintain shape stability by reaching the winding core portion within less than 1/2 turn.
Solution Approach 2:
Different portions of the winding wire are given different structural characteristics. The return winding portion is specifically configured to reach the winding core portion within less than 1/2 turn, creating a localized structural feature that enhances shape stability without affecting the overall compactness of the multilayer winding structure.
2Stability of the object's composition
If the return winding portion is extended for a long distance to reach the winding core portion, then the wire can be properly positioned, but more turns are required and shape stability deteriorates
Solution Approach 1:
The return winding portion performs its function of reaching the winding core portion with less than 1/2 turn, which is less than a full turn would provide. This partial action is sufficient to achieve the positioning goal while maintaining shape stability and reducing the number of turns required.
Solution Approach 2:
The winding configuration changes the parameter of return winding length from a traditional full turn or longer to less than 1/2 turn. This parameter change optimizes the balance between positioning accuracy, shape stability, and winding complexity.
3Volume of moving object
If the winding layer thickness is suppressed to reduce inductor size, then the inductor volume is reduced, but the return winding portion deteriorates in shape stability
Solution Approach 1:
The return winding portion is given a specific local structure where it reaches the winding core portion within less than 1/2 turn. This localized structural optimization ensures manufacturing precision and shape stability in the return winding portion without increasing the overall winding layer thickness.
Solution Approach 2:
The return winding portion is pre-configured to reach the winding core portion within less than 1/2 turn, establishing a stable structural foundation before completing the full winding process. This preliminary positioning action ensures shape stability is maintained throughout the winding process.
Data Source
AI summary
An inductor including: a core having a winding core portion for winding a winding wire and two flange portions disposed on both ends of the winding core portion; and a winding wire wound around the winding core portion for multiple layers, the winding wire including: a forward winding layer having multiple turns on the winding core portion along a forward direction from one of the two flange portions toward the other flange portion; a backward winding layer following the forward winding layer and having at least one turn on the forward winding layer along a backward direction opposite to the forward direction; and a return winding portion following the backward winding layer and passing over the backward winding layer in the forward direction to reach the winding core portion on the forward direction side of the forward winding layer within less than 1/2 turn.