Sparse Multi-Layer Twisted-Wire Coil for Inductance and Mode Control
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Solution Overview
Problem
Conventional coil components with twisted wires face challenges in achieving smaller size or higher inductance due to increased length requirements and mode conversion characteristic deterioration when wound directly on the winding core part.
Innovation Solution
A coil component design featuring a twisted wire portion with multiple layers wound in an overlapping manner, where the second layer is sparsely wound with fewer turns than the first layer, reducing line capacity and maintaining mode conversion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the twisted wire portion is wound directly around the winding core part to increase the number of turns, then the inductance increases, but the length of the winding core part increases and the mode conversion characteristics deteriorate
Solution Approach 1:
The patent transitions from a single-layer winding configuration to a multi-layer winding configuration, utilizing the vertical dimension (radial direction from the core) to accommodate additional turns. The second layer is wound on top of the first layer, allowing the coil to achieve higher inductance without extending the axial length of the winding core part.
Solution Approach 2:
The patent implements a nested winding structure where the second layer of the twisted wire portion is wound on top of the first layer. This nesting arrangement allows multiple layers of turns to be compacted within the same axial space, increasing the number of turns per unit length while maintaining the original core length.
2Quantity of substance
If the twisted wire portion is wound in multiple layers to increase the number of turns, then the inductance increases, but the mode conversion characteristics deteriorate due to increased line capacity from overlapping wires
Solution Approach 1:
The patent applies different winding densities to different layers: the first layer is wound with a standard density to achieve the base number of turns, while the second layer is intentionally sparsely wound with fewer turns. This local differentiation in winding density reduces the overlapping area between layers, thereby reducing line capacity and preserving mode conversion characteristics.
Solution Approach 2:
The patent changes the winding parameter (number of turns per layer) between different layers. Specifically, the second layer is designed with fewer turns than the first layer, creating a sparse winding pattern that reduces capacitive coupling between adjacent turns while still contributing to the overall inductance.
Data Source
AI summary
A coil component comprising a core having a winding core part, and a coil wound around the winding core part and including a plurality of wires. The coil includes a twisted wire portion in which the plurality of wires is twisted together. The twisted wire portion includes a bank region including a first layer wound multiple turns continuously around the winding core part and a second layer wound on the first layer continuously from the first layer. The bank region is sparsely wound with the number of turns of the second layer reduced by two or more as compared to the number of turns of the first layer.