Overlapping Bobbin Coil Layout for Compact High-Voltage Insulation
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Solution Overview
Problem
Conventional coil devices face challenges in achieving compactness without compromising voltage resistance due to the arrangement of wires and cores, leading to increased length and potential voltage resistance decline.
Innovation Solution
The coil device incorporates a first bobbin and a second bobbin with overlapping tubular parts, an intermediate part with corrugations, and a cover with corrugations to extend creepage distances and maintain insulation, allowing for a compact design without reducing voltage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first wound part and the second wound part are arranged along the axial direction of the bobbin, then the installation spaces for the wires are secured, but the length of the bobbin in the axial direction becomes long, making the coil device non-compact
Solution Approach 1:
The patent transitions from a one-dimensional axial arrangement to a two-dimensional radial arrangement by placing the first and second wound parts side-by-side in the radial direction of the bobbin. This dimensional change allows both wound parts to be accommodated within the same axial length, reducing the overall axial length of the coil device while providing sufficient installation space for both wires.
2Adaptability or versatility
If multiple electric conductive members are used to achieve functionality, then the device can perform required functions, but the distance between conductive members becomes short, causing voltage resistance to decline
Solution Approach 1:
The patent introduces an intermediate part as a mediator between the second tubular part and the terminal block. This intermediate part includes a corrugation structure that acts as an insulation barrier, preventing direct current paths between the second wire (second wound part) and the terminal. The corrugation creates extended creepage distance and acts as an intermediary insulation layer, thereby maintaining voltage resistance despite the close proximity of multiple conductive members.
3Length of moving object
If the tubular parts are arranged in overlapping manner to make the device compact, then the axial length is reduced, but the insulation distance between wires and terminals may be compromised
Solution Approach 1:
The patent utilizes the radial dimension to solve the insulation distance problem. While the axial length is reduced through overlapping tubular parts, the intermediate part extends in the radial direction with its corrugation structure. This radial extension creates sufficient creepage distance and insulation clearance between the second wound part and the terminal, maintaining reliability despite the compact axial arrangement.
Solution Approach 2:
The corrugation structure on the intermediate part introduces a curved, three-dimensional surface that increases the creepage distance between conductive elements. The undulating surface of the corrugation creates a longer electrical path compared to a flat surface, thereby maintaining adequate insulation distance within the compact overall dimensions of the device.
Data Source
AI summary
A coil device includes a first tubular part 41, a first bobbin 40 including a terminal block 42 provided with a terminal 30b, a first wound part 11 placed on the first tubular part 41, a first wire 10 pulled out from the first wound part 11 and connected to the terminal 30b, a second tubular part 51 accommodating the first tubular part 41, a second tubular part 21 placed on the second tubular part 51, and a second wire 20 including a second part 22b pulled out from the second wound part 21 to the opposite side to the first lead-out part 12b. An intermediate part has a corrugation on the outer surface.