Layered Coil Winding Layout for Capacitance Balance
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Solution Overview
Problem
In coil components, such as common mode choke coils, inadvertent positional shifts of wires during the winding process can lead to imbalanced capacitance and deteriorated mode conversion characteristics due to unintentional stepping of turns, resulting in reduced performance.
Innovation Solution
The coil component design includes specific winding configurations where the first and second wires are wound in alternating layers, with transfer portions guiding the wires to different layers to prevent positional shifts, and strategically placed shift areas to balance capacitance, reducing stray capacitance and mode conversion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wires are wound in a state of forming multiple layers around the winding core portion, then the coil component can achieve compact structure and high winding density, but positional shifts of wires during the winding process occur, leading to imbalanced capacitance and deteriorated mode conversion characteristics
Solution Approach 1:
The patent applies preliminary action by forming transfer portions that guide wires between layers before the winding process is completed. These transfer portions are created in advance to prevent positional shifts during subsequent winding operations, ensuring that wires are correctly positioned when transitioning between the first and second layers around the winding core portion.
Solution Approach 2:
The patent uses transfer portions as intermediary structures that facilitate the transition of wires between different layers. These transfer portions act as mediators that guide the wires from the first layer to the second layer, preventing direct contact and positional shifts that would otherwise occur during the winding process, thereby maintaining manufacturing precision while achieving high winding density.
2Reliability
If wires are wound with significant shift between turns to balance capacitance, then mode conversion characteristics improve, but stray capacitance increases
Solution Approach 1:
The patent applies local quality by creating specific shift areas with controlled shift amounts (0.5 turns to 2.0 turns) at particular locations along the winding, while maintaining minimal shift in other areas. This localized approach to wire positioning allows capacitance balancing in critical regions without unnecessarily increasing stray capacitance across the entire coil structure, thereby improving mode conversion characteristics while minimizing harmful effects.
Data Source
AI summary
A coil component includes first and second wound areas along an axis direction of a winding core portion. In the first wound area, a first wire is wound as a first layer. A second wire is wound as a second layer in a recessed portion between adjacent turns of the first wire, returned from an end portion on a second end portion side to a first end portion side and guided to an outer peripheral side of the second layer, wound as a third layer, guided to a position of the second layer on an outer peripheral side of the first layer, and wound as the second layer in a recessed portion between adjacent turns of the first wire of the first layer. In the second wound area, a layer in which each of the first and second wires in the first wound area is located is replaced.