Twisted-Wire Coil Winding Structure for High Inductance

The patent transitions from a single-layer winding to a multi-layer winding structure, adding the dimension of layer stacking. The wire assembly is wound in multiple layers around the winding core portion, with each layer positioned at different radial distances from the core. This dimensional change enables significantly more turns to be accommodated within the same axial length, thereby achieving the required high inductance without increasing the overall component size.

The patent implements a nested winding structure where multiple layers of the wire assembly are wound concentrically around the winding core portion. The first layer is wound directly on the core, the second layer is wound on top of the first layer, and so on. This nesting approach allows the wire turns to be packed efficiently in three-dimensional space, maximizing the number of turns within a compact cylindrical volume and achieving high inductance without proportionally increasing component size.

The patent compensates for the space loss from twisted wire unevenness by utilizing the radial dimension through multi-layer winding. While the twisted wire structure creates gaps in the radial direction, the multi-layer approach fills the axial and circumferential dimensions efficiently. The cumulative effect of multiple layers compensates for the space wastage in each individual layer, enabling sufficient number of turns to be achieved while maintaining the beneficial mode conversion characteristics of twisted wires.