Pulse Transformer Coil Layout for Bifilar Winding With Different Turns
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Solution Overview
Problem
Existing coil components for pulse transformers require complex winding operations due to the need for opposite winding directions of paired wires and differing numbers of turns between primary and secondary coils, leading to time-consuming and prone-to-interference winding processes.
Innovation Solution
A coil component design featuring bifilar wound wires with distinct crossing areas and terminal electrode configurations that allow for simplified winding and center tap formation, enabling easier assembly and reduced interference, even when the primary and secondary coils have different numbers of turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If two terminal electrodes constituting the center tap are provided on the same flange part, then the connection structure is compact, but the wire winding operation becomes complex requiring mutually opposite directions
Solution Approach 1:
The patent divides the terminal electrodes into two separate groups: center tap electrodes on the first flange part and other terminal electrodes on the second flange part. This segmentation allows wires to be wound in a single direction without requiring opposite winding directions, simplifying the winding operation while maintaining compact connection structure.
2Adaptability or versatility
If four wires are wound one by one to accommodate different turn numbers, then the primary and secondary coils can have different turns, but the winding operation takes excessive time
Solution Approach 1:
The patent merges the winding operations by providing two pairs of wires (first and second wires, third and fourth wires) that are bifilar wound together. Both pairs can be wound simultaneously in the same direction, allowing different turn numbers between primary and secondary coils while significantly reducing winding time compared to sequential single-wire winding.
3Ease of operation
If the first and second wires are bifilar wound and cross each other, then the winding operation is facilitated, but wire breakage and winding collapse may occur due to interference
Solution Approach 1:
The patent resolves wire interference by positioning the crossing area of the first and second wires at a different location from the crossing area of the third and fourth wires along the winding direction. This spatial separation in the longitudinal dimension prevents wire breakage and winding collapse while maintaining the benefits of bifilar winding and crossing for simplified operations.
Data Source
AI summary
Disclosed herein is a coil component that includes a core, first to fourth terminal electrodes provided on a first flange part, fifth to eighth terminal electrodes provided on a second flange part, first and second wires bifilar wound around a winding core part, and third and fourth wires bifilar wound around the winding core part. One and other ends of the first to eighth wires are connected corresponding one of the first to eighth terminal electrodes. The first and second wires cross each other in a first crossing area. The third and fourth wires cross each other in a second crossing area different from the first crossing area.