Laminated Planar Coil Structure for Vibration-Resistant Insulation
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Solution Overview
Problem
Laminated planar coils are prone to displacement and deformation due to vibration, leading to potential short-circuiting between turns, which is not adequately addressed in existing technologies without a rigid substrate.
Innovation Solution
A laminated coil structure with film-like insulating members between adjacent planar coils and cores, sandwiched by fixing members to prevent displacement and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If planar coils are laminated without a rigid substrate, then the device complexity is reduced and manufacturing is simplified, but the coils are prone to displacement and deformation due to vibration, leading to short-circuiting between turns
Solution Approach 1:
An insulating member is introduced as an intermediary element between adjacent planar coils to prevent direct contact and potential short-circuiting. This mediator maintains the necessary insulation while allowing the coils to be laminated without requiring a rigid substrate, thus resolving the contradiction between simplified structure and short-circuit resistance.
Solution Approach 2:
The insulating member is configured as a thin film structure that provides sufficient insulation between coils while maintaining flexibility. This thin film approach prevents short-circuiting without imposing the rigidity of a substrate, enabling simplified device structure while ensuring reliability against vibration-induced displacement.
2Volume of moving object
If the cross-sectional area of the coil is reduced to downsize the transformer, then the productivity and compactness are improved, but the electrical resistance increases, leading to larger temperature increase due to conduction loss
Solution Approach 1:
The patent transitions from traditional three-dimensional wound coils to two-dimensional planar coil structures. This dimensional change allows for more efficient current distribution and reduced skin effect at high frequencies, enabling smaller transformer size while managing conduction losses and temperature increase through the planar geometry.
3Volume of moving object
If the switching frequency is increased to downsize the transformer, then the transformer size is reduced, but heat generated from the coil increases due to skin effect
Solution Approach 1:
The planar coil structure provides a larger effective surface area for current flow compared to traditional wound coils of equivalent size. This dimensional change reduces the skin effect by distributing current more evenly across the conductor cross-section, thereby reducing conduction losses while maintaining high switching frequencies and compact transformer size.
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
Suppresses short-circuiting between turns in planar coils even without a rigid substrate, ensuring stable operation under vibrational conditions.
Implementation Method 1
a first insulating member which is arranged between a pair of planar coils adjacent to each other in the first direction among the planar coils and is in a film form
Implementation Method 2
a second insulating member which is arranged between turns adjacent to each other in the second direction of the at least one planar coil
Implementation Method 3
sandwiched by fixing members to prevent displacement and deformation
Data Source
AI summary
A laminated coil includes planar coils and a first insulating member. The planar coils are arranged in a first direction intersecting a first surface. The first insulating member is in a film form and arranged between a pair of planar coils adjacent to each other in the first direction. At least one of the planar coils is wound to have a plurality of turns spaced apart from each other in a second direction along the first surface. A second insulating member is arranged between the turns adjacent to each other in the second direction of at least one of the planar coils.