Integrated Coil Component Design for Magnetic Coupling Reduction
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Solution Overview
Problem
The challenge is to reduce the size and weight of AM/FM radio-wave receivers by minimizing the number of coil components while preventing magnetic coupling between coils with different functions, which increases the size and weight of the mounting substrate and raises costs.
Innovation Solution
A coil component design featuring a first coil and a drum core with a second and third coil wound around a shared winding groove, where the number of windings in each coil is optimized to minimize magnetic coupling, with the magnetic flux paths configured to prevent interference and maintain desired inductance values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple coil components with different functions are mounted on the mounting substrate, then the radio-wave receiver can possess multiple functions (receiving and filtering), but the mounting substrate becomes large and the weight of the electronic device increases
Solution Approach 1:
The patent combines multiple coil components with different functions into a single integrated coil component. The first coil for receiving and second coil for filtering are wound on separate winding grooves of the same drum core, merging multiple functional components into one physical unit, thereby reducing the number of components to be mounted and decreasing device weight
Solution Approach 2:
The drum core structure serves multiple purposes: it provides winding grooves for both the first coil (receiving function) and second coil (filtering function), acts as a magnetic path for both coils, and integrates multiple functions into a single component structure, enabling one component to perform multiple functions
2Adaptability or versatility
If multiple coil components are mounted on the mounting substrate, then the radio-wave receiver can possess multiple functions, but the mounting substrate area increases requiring larger device size
Solution Approach 1:
Multiple coil components are merged into a single integrated component with multiple winding grooves on one drum core. This consolidation reduces the number of discrete components from multiple separate coils to one multi-functional coil component, thereby reducing the mounting substrate area required
Solution Approach 2:
The patent utilizes the vertical dimension by creating multiple winding grooves at different positions on the drum core (first winding groove and second winding groove). This three-dimensional arrangement allows multiple coils to be stacked or arranged vertically rather than occupying separate horizontal spaces, reducing the mounting substrate area
3Productivity
If plural coils are wound in one coil component, then the number of coil components to be mounted is reduced, but magnetic coupling occurs making it difficult to set desired inductance values
Solution Approach 1:
The drum core is divided into separate winding grooves (first winding groove and second winding groove) that are spatially separated. This segmentation physically isolates the first coil and second coil within the same component structure, reducing magnetic coupling between them while maintaining controlled inductance values for each coil function
Solution Approach 2:
Each winding groove is designed with specific local characteristics (position, size, orientation) optimized for its intended coil function. The first winding groove is positioned and sized for the receiving coil, while the second winding groove is positioned and sized for the filtering coil, allowing each coil to achieve its desired inductance independently
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 the size and weight of the AM/FM radio-wave receiver by minimizing the number of coil components, maintains high reception accuracy, and lowers manufacturing costs by reducing the size of the mounting substrate and minimizing magnetic coupling.
Implementation Method 1
a magnetic flux generated from the first coil (31) passes through magnetic paths formed from the drum core (16) and the pot core (23)
Implementation Method 2
a coil component having plural coils wound therein is known... magnetic coupling occurs in a portion where magnetic fluxes commonly pass through
Implementation Method 3
magnetic paths formed from the drum core (16) and the pot core (23)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A coil component having a first coil, a second coil, a third coil, each of which has a different function, an upper flange, and a lower flange, and also including a drum core in which a first winding groove having the first coil wound around is formed, and a base member having a winding shaft provided in a bottom portion, wherein a second winding groove is formed between the lower flange and the bottom portion, and the second coil and the third coil are wound around this second winding groove when the drum core and the base member are assembled together.