Spiral Coil End-Surface Layout for Compact Inductor Performance
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Solution Overview
Problem
Existing coils face a challenge in achieving both size reduction and maintaining coil characteristics, as simply reducing the coil diameter leads to a decrease in the inner magnetic path area, thereby deteriorating coil performance.
Innovation Solution
A coil design featuring a spirally wound wire with specific end surface configurations, including first and second wiring portions with strategically positioned end surfaces to minimize magnetic flux hindrance, allowing for both size reduction and improved coil characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil diameter is reduced to achieve size reduction, then the coil size is reduced, but the inner magnetic path area is reduced and coil characteristics deteriorate
Solution Approach 1:
The patent applies local quality by creating asymmetric end surfaces at different positions along the coil wire. The first end surface is positioned at a first location while the second end surface is positioned at a second location different from the first, allowing different regions of the coil wire to have optimized local characteristics. This enables the coil to maintain effective magnetic path area while achieving size reduction, as the asymmetric configuration optimizes magnetic flux distribution in different sections of the coil.
2Volume of moving object
If the coil diameter is reduced to achieve size reduction, then the coil size is reduced, but the magnetic flux is hindered by the coil wire and coil characteristics deteriorate
Solution Approach 1:
The patent applies asymmetry by configuring the coil wire with non-symmetric end surfaces at different positions. The first end surface and second end surface are positioned asymmetrically along the coil wire, which optimizes the magnetic flux path and reduces self-hindrance effects. This asymmetric configuration allows the reduced-size coil to maintain effective magnetic coupling and reduce the harmful effect of magnetic flux being blocked by the coil wire itself.
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 design enables effective size reduction while maintaining coil characteristics comparable to larger coils, by optimizing the placement and shape of end surfaces to reduce magnetic flux interference within the coil wire.
Implementation Method 1
a coil wire (20) spirally wound along an axis L
Data Source
AI summary
A coil that includes a coil wire spirally wound along an axis. The coil wire includes a first wiring portion and a second wiring portion which are aligned along the axis. The first wiring portion includes a first end surface on a side in a first direction from the first wiring portion toward the second wiring portion, and a second end surface on a side in a second direction opposite to the first direction. The first end surface includes a first end in an inner side portion in a radial direction of the coil wire. The second end surface is in an outer side portion in the radial direction of the coil wire with respect to a straight line passing through the first end and parallel to the direction of the axis.