Inductor Wire Structure for Uniform Current Distribution
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Solution Overview
Problem
Inductors with coaxially wound wires suffer from an imbalance in current distribution, leading to joule loss due to alternating current, as the wires in the middle portion are never exposed to the inner or outer circumference, and those at the circumference are not in the middle portion, resulting in non-uniform wire length and current distribution.
Innovation Solution
The inductor design includes multiple wires with an outer-winding helical portion that shifts axially while increasing radius, an inner-winding helical portion that shifts while reducing radius, and a connection portion connecting these at different axial positions, ensuring uniform wire length and current distribution by arranging outer and inner helical portions in a cyclical pattern to prevent touching and achieve balanced electric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wires are simply reversed in arrangement order to uniformize wire length, then wire length uniformity is improved, but current distribution imbalance persists because middle portion wires are never exposed to inner or outer circumference
Solution Approach 1:
The wire is divided into multiple segments along its length, with each segment positioned at different radial locations (inner circumference, middle portion, outer circumference). This segmentation allows different portions of the same wire to experience different magnetic flux conditions, thereby achieving more uniform current distribution across all wire segments and reducing overall joule loss.
Solution Approach 2:
The invention transitions from a simple radial arrangement to a three-dimensional configuration where wires are positioned at multiple axial locations. By utilizing the axial dimension in addition to the radial dimension, the patent ensures that wires at different radial positions are compensated, achieving uniform current distribution and reducing energy loss.
2Reliability
If small diameter wires are used to reduce skin effect, then high-frequency signal performance is improved, but wire length imbalance and current distribution issues worsen due to simplified reversal arrangement
Solution Approach 1:
Different segments of the wire structure are assigned different local qualities or positions. Specifically, wires are positioned at different radial and axial locations to create local variations in magnetic flux exposure. This local quality differentiation ensures that each wire segment operates under optimized conditions, reducing overall energy loss while maintaining high-frequency performance.
3Device complexity
If wires are arranged with inner and outer circumference positions fixed, then structural simplicity is maintained, but wire length and current distribution uniformity deteriorate
Solution Approach 1:
The wire arrangement incorporates dynamic positioning where wires are placed at multiple axial locations rather than fixed radial positions only. This dynamic three-dimensional arrangement allows the structure to adapt to magnetic flux distribution patterns, achieving uniform current distribution without significantly increasing structural complexity.
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 design reduces current distribution imbalance, resulting in a low-loss inductor with improved electric characteristics and efficient performance, which can be used to create a small-sized, low-loss transformer with enhanced frequency response.
Implementation Method 1
the wires located in the middle portion in the radial direction are never exposed to the inner circumference or the outer circumference... the wires fail to have precisely uniform wire length, and may have an imbalance in current distribution in the wires
Data Source
AI summary
An inductor includes a plurality of wires disposed about an axis, a first electrode connected to a first end of each of the plurality of wires, and a second electrode connected to a second end of each of the plurality of wires. Each of the wires includes an outer-winding helical portion shifting in an axial direction while gradually increasing a radius thereof, an inner-winding helical portion shifting in the axial direction while gradually reducing a radius thereof, and an outer circumference connection portion that connects an end of the outer-winding helical portion and an end of the inner-winding helical portion at different positions in the axial direction.