Twisted-Wire Inductor for Compact Volume and High Voltage
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Solution Overview
Problem
Conventional inductors face challenges in balancing inductance characteristics with size and manufacturing cost due to their structure, which requires larger components and increased PCB board size for proper functioning.
Innovation Solution
The inductor design features twisted primary-side and secondary-side wires, center-tapped protrusions, and a housing with welding protrusions, allowing for a compact structure with reduced volume and increased withstand voltage, and a simplified production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding portion length is increased to accommodate more wire turns for higher inductance, then the inductance characteristic is improved, but the inductor size increases
Solution Approach 1:
The patent transitions from a linear winding arrangement to a three-dimensional cylindrical winding structure. The wire is wound around a cylindrical winding portion with diameter D, allowing the wire to utilize spatial volume rather than just linear length. This dimensional change enables achieving the required inductance with a more compact overall structure, as the magnetic field is distributed in three dimensions around the cylinder rather than along a straight line.
2Ease of operation
If four wire accommodating portions are provided for each enameled wire terminal, then proper wire connection is achieved, but the PCB board size and manufacturing cost increase
Solution Approach 1:
The patent merges the terminal connection functions by providing only two wire accommodating portions instead of four. The cylindrical winding structure allows the enameled wires to be connected at both ends of the cylinder, with the wire ends emerging from opposite sides. This consolidation reduces the number of separate connection points required on the PCB board from four to two, thereby reducing the PCB board area and manufacturing cost while maintaining proper wire connection functionality.
Data Source
AI summary
The present invention relates to an inductor, wherein the inductor according to the present invention includes: a body, a winding wire winded around the body, and a housing used for covering the body, according to the present invention, the inductor reduces the volume and increases the withstanding voltage of inductor by twisting the wires, and the present invention also provide a production method of the inductor can simplify the production process of inductors.