Twisted-Strand Magnetic Module for High-Frequency Signal Transmission
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Solution Overview
Problem
Existing magnetic modules face challenges in high-frequency signal transmission due to high resistance at input and output ends of coils, leading to impaired flexibility and paint rupture during winding, which affects the efficiency of signal transmission.
Innovation Solution
A magnetic module design involving twisted enameled wires, where groups of wires are twisted together to form stranded wires, enhancing flexibility and reducing impedance, thereby supporting effective high-frequency signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thickening the enameled wire is used to reduce impedance, then impedance is reduced, but the enameled wire has greater tension during winding and bending, causing paint rupture and deteriorated flexibility
Solution Approach 1:
The wire is divided into multiple thin enameled wires (e.g., 7 strands) twisted together to form a composite conductor. This segmentation allows each individual wire to remain flexible and easy to wind, while the combined structure achieves the required current carrying capacity and lower impedance without the tension and paint rupture issues of a single thick wire.
2Ease of manufacture
If using thin enameled wires, then flexibility and ease of winding are improved, but resistance increases, impairing high-frequency signal transmission
Solution Approach 1:
Multiple thin enameled wires are twisted together to form a single composite conductor. This merging combines the advantages of thin wires (flexibility, ease of winding) while achieving the electrical performance of a thicker wire (lower resistance and impedance), enabling effective high-frequency signal transmission.
3Ease of manufacture
If using traditional non-twisted coil winding, then manufacturing is simpler, but high-frequency signal transmission efficiency is reduced due to high impedance
Solution Approach 1:
The patent introduces a twisted strand structure where multiple wires are twisted together before winding onto the magnetic core. This dynamic configuration reduces the skin effect and proximity effect at high frequencies, lowering impedance and improving signal transmission efficiency while maintaining manufacturing feasibility through standardized twisting processes.
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
The twisted wire configuration achieves lower impedance and higher inductance, ensuring better high-frequency characteristics with reduced insertion loss, reflection loss, and crosstalk, enabling efficient signal transmission up to 25 Gbps.
Implementation Method 1
the resistance of each input end and output end is relatively large, which cannot guarantee the effective transmission of high-frequency signal transmission. However, in order to reduce the impedance, thickening the enameled wire will cause the enameled wire to have a greater tension during the winding and bending process
Implementation Method 2
A magnetic module comprises: a magnetic core; and a plurality of enameled wires wound on the magnetic core, the enameled wire being wound on the magnetic core to form a primary coil and a secondary coil
Data Source
AI summary
A magnetic module includes: a magnetic core; and plural enameled wires wound on the magnetic core, the enameled wire being wound on the magnetic core to form a primary coil and a secondary coil, the primary coil including a first group of enameled wires and a second group of enameled wires, the secondary coil including a third group of enameled wires and a fourth group of enameled wires, wherein the parts of the first group of enameled wires and the fourth group of enameled wires wound around the magnetic core are twisted together to form a first stranded wire, the parts of the second group of enameled wires and the third group of enameled wires wound around the magnetic core are twisted together to form a second stranded wire, and the first stranded wire and the second stranded wire are twisted together to form a total stranded wire.