Segmented Coil Component with Welded Wire Joints
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Solution Overview
Problem
The existing coil components with thick wires experience a winding bulge issue, leading to increased size when a large current is required, making them inefficient in terms of size and current flow.
Innovation Solution
A method of manufacturing a coil component using alternately joined first and second wire members around a toroidal core, where the second wire members are fitted between the first wire members and joined by welding, reducing the size and resistance of the coil while allowing a large current to flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thick wire is used to allow a large current to flow through the coil, then the current carrying capacity is improved, but the winding bulge increases and the coil component size becomes larger
Solution Approach 1:
The coil is segmented into multiple thin wire members (first wire members and second wire members) arranged in parallel around the core. Instead of using a single thick wire, the current path is divided into multiple parallel paths, allowing the coil to carry large current while maintaining a compact size without winding bulge.
2Quantity of substance
If a thick wire is used to allow a large current to flow through the coil, then the current carrying capacity is improved, but the minimum radius at the inner side of the wire increases
Solution Approach 1:
The thick wire is segmented into multiple thin wire members arranged in parallel. This segmentation allows the coil to achieve the required current carrying capacity while maintaining a smaller minimum radius at the inner side, as each thin wire member can be bent more sharply without excessive stress.
3Quantity of substance
If multiple wire members are joined together to form the coil, then the current carrying capacity is improved, but the manufacturing complexity increases
Solution Approach 1:
The coil is segmented into multiple wire members that are joined at discrete points (joining portions) around the core. This segmentation approach, combined with automated welding processes, achieves the required current carrying capacity while keeping manufacturing complexity manageable through standardized joining procedures.
Solution Approach 2:
The joining of wire members is achieved through welding (thermal process) rather than mechanical fastening methods. This substitution simplifies the manufacturing process by eliminating the need for complex mechanical assembly operations, reducing manufacturing complexity while maintaining electrical connectivity.
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
This configuration minimizes the winding bulge, reduces the size of the coil component, and decreases the resistance value, enabling a larger current to flow efficiently while maintaining a compact size.
Implementation Method 1
the first wire members and the second wire members be joined together by welding portions which are formed by melting the first wire members and the second wire members
Implementation Method 2
forming a coil wound around the core by the first wire members and the second wire members by welding the side surfaces of the joining portions and the joining surfaces
Implementation Method 3
the third step include forming the plurality of welding portions for joining the side surfaces of the plurality of joining portions and the plurality of joining surfaces by emission of laser light
Data Source
AI summary
A coil component includes an annular core and a first coil and a second coil wound around the core. The first coil and the second coil include first wire members and second wire members. The second wire members have end surfaces and which are brought into contact with side surfaces of first and second joining portions at tips of the first wire members. The first wire members and the second wire members are joined to each other with welding portions between the side surfaces of the first and second joining portions at the tips of the first wire members and the end surfaces of the second wire members interposed therebetween.