Partial-Turn Coil Fixation for Low-Inductance PCB Mounting

Solution Overview

Problem

Conventional coils with complete turns face challenges in achieving low inductance, low DC resistance, and low AC impedance while maintaining secure handling and automatic production, especially when the winding angle is less than 180°.

Innovation Solution

A coil design featuring a winding that extends up to 290° around a magnetic core, with latching elements and a shielding ring, allowing for secure fixation and easy handling, and utilizing materials like copper for low resistance, and incorporating a groove or protrusion for secure mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the winding extends by a small angle around the core, then the inductance is reduced, but the winding becomes difficult to hold securely on the core

Engineering Contradiction:

ImproveinductanceVSAvoidhandling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Latching elements are pre-formed on the winding structure before mounting, enabling secure attachment to the core without requiring complex assembly operations or tools during the mounting process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Latching elements act as intermediary components that mediate between the winding and the core, providing a secure mechanical connection that holds the winding firmly on the core while allowing for easy assembly and disassembly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the winding extends by a small angle around the core, then the inductance is reduced, but the coil becomes unsuitable for automatic production and mounting

Engineering Contradiction:

ImproveinductanceVSAvoidautomatic production

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

Latching elements are pre-formed on the winding structure before mounting, enabling secure attachment to the core without requiring complex assembly operations or tools during the mounting process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Latching elements act as intermediary components that mediate between the winding and the core, providing a secure mechanical connection that holds the winding firmly on the core while allowing for easy assembly and disassembly

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If conventional fixing methods are used for windings with small angles, then the structure becomes complex, but simple fixing methods are insufficient for secure mounting

Engineering Contradiction:

ImprovestructureVSAvoidfixing

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Latching elements are pre-formed on the winding structure before mounting, enabling secure attachment to the core without requiring complex assembly operations or tools during the mounting process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Latching elements act as intermediary components that mediate between the winding and the core, providing a secure mechanical connection that holds the winding firmly on the core while allowing for easy assembly and disassembly

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design achieves very low inductance values, low DC resistance, and high saturation current, facilitating easy handling and automatic production, while allowing for space-saving configurations and secure mounting on printed circuit boards.

Implementation Method 1

A coil (10) having an electrically conductive winding (14), wherein the winding (14) has a first winding connection (18) and a second winding connection (20), and having a magnetic core (12)

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20240021359A1Coil, process for manufacturing a coil, and assembly

Publication Date: 2024.01.18 WURTH ELEKTRONIK EISOS

AI summary

The invention relates to a coil having an electrically conductive winding, wherein the winding has a first winding connection and a second winding connection, and having a magnetic core, in which the winding extends up to a maximum angle of 290°, in particular 270°, around the core, and the winding is fixed to the core.