Spherical Induction Device Coil Turns Voltage Transformation
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Solution Overview
Problem
Existing induction devices face a challenge in increasing the number of coil turns without enlarging the device size, particularly in stepping down high voltages like 200-300 volts to 12 volts for hybrid vehicles, due to limitations in the spaced distance between coil turns and the need for compactness.
Innovation Solution
The induction device incorporates a first coil formed by winding a conductive wire with an insulating layer, a second coil made of a metal pattern, and a coil support member between them, allowing for magnetic connection and increased turns without size enlargement, along with a transformer configuration that includes a primary coil, secondary coil, and an insulating sheet for efficient voltage stepping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of turns of the coil is increased to step down voltage from 200-300 volts to 12 volts, then the voltage transformation ratio is improved, but the coil size is enlarged in the radial direction
Solution Approach 1:
The patent transitions from planar coil winding to three-dimensional spherical coil winding. By arranging conductive wires radially around a spherical core, the coil utilizes the third dimension (radial direction) to accommodate multiple turns without increasing the planar area. This dimensional change allows achieving the required voltage transformation ratio while maintaining a compact coil footprint.
Solution Approach 2:
The patent implements nested coil structures where multiple layers of conductive wires are wound around each other in a spherical configuration. The wires are arranged concentrically with different radial distances from the spherical core, creating a nested arrangement that maximizes the number of turns within a limited volume without radial enlargement.
2Quantity of substance
If the spaced distance between adjacent turns of coil is reduced to increase turns per unit area, then the number of turns is increased, but the manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent employs flexible conductive wires with insulating coatings that can be tightly wound around the spherical core. The thin film insulation layer allows adjacent turns to be placed very close together while maintaining electrical isolation. This flexible winding approach enables precise control of turn spacing through mechanical winding tension rather than requiring complex precision manufacturing processes.
Solution Approach 2:
The patent changes the geometric parameters of the coil structure by adopting a spherical configuration instead of planar winding. This parameter change allows the use of radial distance as a control variable for turn spacing, where the spacing is naturally determined by the wire diameter and winding tension rather than requiring precise dimensional control in multiple directions as in planar coils.
3Power
If the number of turns of the coil is increased without size enlargement, then the power handling capacity is enhanced, but the device complexity increases
Solution Approach 1:
The patent combines multiple functional elements into a unified spherical coil structure. The spherical core, conductive wires, insulating layers, and support structure are integrated into a single compact assembly rather than separate components. This merging reduces the overall device complexity despite achieving a high number of turns, as the spherical geometry provides a natural organizing framework that simplifies the arrangement and interconnection of all coil elements.
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 enables a higher number of coil turns without size increase, enhancing power handling capacity, reducing part count and cost, and improving heat management through efficient radiation, while maintaining compactness and durability.
Implementation Method 1
an induction device that operates on electromagnetic induction
Data Source
AI summary
There is provided an induction device including a first coil formed by winding a plurality of times a conductive wire that is covered with an insulating layer, a second coil formed of a metal pattern, and a coil support member disposed between the first coil and the second coil. The first coil and the second coil are magnetically connected to each other. There is also provided a transformer including a primary coil formed by winding a plurality of times a conductive wire that is covered with an insulating layer, a secondary coil formed of a metal pattern, and an insulating sheet that is disposed between the primary coil and the secondary coil. The primary coil and the secondary coil are magnetically connected to each other.