Laminate Coil Inner-End Sealing to Prevent Core Short Circuits
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Solution Overview
Problem
Planar coils with laminated windings and insulating layers are prone to positional displacement and deformation due to vibration, expansion, or heat, leading to short circuits between the coil and core, which degrade the transformer's characteristics.
Innovation Solution
A laminate coil manufacturing method involving the lamination of flat conductor coils with multilayer insulating members, where through-holes penetrate the coils, and pressing elastic members are used to bond the insulating members and seal the inner ends, preventing exposure and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of windings are laminated with insulating layers interposed therebetween, then the coil structure can be formed, but positional displacement and deformation of windings occur due to vibration, heat expansion, or contraction, leading to short circuits between the winding and core
Solution Approach 1:
The patent applies preliminary action by forming through-holes in the insulating layers before final assembly, and by pre-positioning pressing elastic members within these through-holes. This preparatory structuring ensures that when the coil assembly is subjected to vibration or thermal changes, the pressing elastic members are already in place to maintain winding position and prevent short circuits, rather than requiring corrective action after displacement occurs.
Solution Approach 2:
The patent introduces pressing elastic members as intermediary elements between the windings and the core/insulating structure. These elastic members act as mediators that absorb mechanical stress from vibration and thermal expansion, maintaining electrical isolation between the winding and core while accommodating dimensional changes. The elastic material specifically serves as a buffer that prevents direct contact between conductive parts.
2Reliability
If the coil is constrained to prevent displacement, then short circuit prevention is improved, but the device complexity increases due to additional pressing members and bonding structures
Solution Approach 1:
The patent employs pressing elastic members made of flexible elastic material that can deform under compression to provide continuous contact pressure. These flexible elements conform to the winding shape and provide adaptive constraint without requiring rigid structural frameworks. The elasticity allows the constraint mechanism to accommodate thermal expansion and contraction while maintaining positioning, reducing the need for additional rigid support structures.
Solution Approach 2:
The patent implements nesting by placing pressing elastic members inside through-holes that are formed within the insulating layers and coil structure. This nested arrangement integrates the constraint function into the existing layered structure rather than adding external components. The pressing members are embedded within the through-holes, which are themselves part of the insulating layer architecture, creating a compact integrated solution that minimizes overall device 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
The solution effectively prevents short circuits between the coil and core, maintaining the transformer's characteristics and ensuring reliable operation by securely bonding the insulating members around the coils.
Implementation Method 1
disposing a pair of first pressing elastic members so as to sandwich an inner end of the multilayer body in the multilayer direction
Data Source
AI summary
A laminate coil is formed by laminating a plurality of multilayer insulating members such that a first coil, a second coil, and a third coil each formed of a flat conductor are sandwiched between the plurality of multilayer insulating members. In the laminate coil, a through-hole is provided inside the coil in planar view. The plurality of multilayer insulating members adjacent to each other in a multilayer direction are bonded to each other at an inner end of the laminate coil positioned on the through-hole side, and an inside end of each of the first coil, the second coil, and the third coil is sealed by the multilayer insulating member.