Wire-Wound Coil With Positioning Protrusions For Impedance Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire-wound coils lack a means to position wires consistently around the core, leading to movement and variations in electrostatic capacitance and characteristic impedance due to unpredictable wire separation.
Innovation Solution
The coils are designed with primary and secondary windings that are partially separated and partially in contact across turns, allowing for adjustable electrostatic capacitance and stable winding by positioning one winding turn section in contact with another across the core surface, maintaining consistent distance between winding centers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are wound around the planar surface of the core portion without positioning means, then the winding process is simple, but the wires move over the surface causing variations in electrostatic capacitance and characteristic impedance
Solution Approach 1:
Positioning protrusions are pre-formed on the core portion surface before winding. These protrusions serve as predetermined positioning points that guide and constrain the wires during the winding process, preventing movement and ensuring consistent positioning without complicating the overall manufacturing process
Solution Approach 2:
The positioning protrusions act as intermediary elements between the core portion and the wires. They provide a mechanical interface that ensures accurate wire placement while maintaining the simplicity of the winding process, solving the contradiction between ease of manufacture and manufacturing precision
2Adaptability or versatility
If wires are separated from each other during winding, then the winding structure is flexible, but the electrostatic capacitance between wires varies widely causing characteristic impedance variations
Solution Approach 1:
The spacing between positioning protrusions is predetermined during core fabrication. This pre-establishes fixed intervals between adjacent wires, ensuring consistent electrostatic capacitance and stable characteristic impedance while still allowing flexible winding configurations to be achieved by adjusting which protrusions are used
Solution Approach 2:
The distance between positioning protrusions can be varied to adjust the spacing between wires. By changing this parameter during core design, the electrostatic capacitance between wires is controlled, enabling both flexibility in winding structures and stability in characteristic impedance
3Ease of manufacture
If the distance between wires cannot be adjusted, then the manufacturing process is simple, but the characteristic impedance cannot be flexibly adjusted
Solution Approach 1:
The core portion surface is segmented into multiple positioning protrusions arranged at different intervals. This segmentation allows selection of different protrusion pairs to achieve different wire spacings and characteristic impedances, providing adjustability while maintaining simple manufacturing through a single core design
Solution Approach 2:
A single core portion with multiple positioning protrusions serves multiple functions: it provides positioning for different wire configurations, enables adjustment of characteristic impedance, and maintains manufacturing simplicity. The same core structure adapts to different electrical requirements through selective use of protrusions
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 prevents variations in characteristic impedance and ensures stable winding by maintaining consistent electrostatic capacitance and preventing wire movement, allowing for flexible adjustment of the interval between windings.
Implementation Method 1
a pair of windings including a primary winding part (18A) and a secondary winding part (18B) wound around the surface of the core portion
Implementation Method 2
the electrostatic capacitance between the wires may vary widely depending on variations in the winding of the wires
Data Source
AI summary
A wire-wound coil has a characteristic impedance that can be flexibly adjusted and can be prevented from varying undesirably. In the coil of the present invention, a primary wire part 18A and a secondary wire part 18B are wound around the surface of a core portion 14 so as to be separated from each other by a fixed distance. At the same time, at least one portion the secondary wire part 18B in a prior turn section 19X and at least one portion of the primary wire part 18A in a subsequent turn section 19Y are in close contact with each other, wherein the wire parts 18A and 18B are wound in different turns and are adjacent to each other on the same surface of the core portion 14. A method for manufacturing the wire-wound coil is also disclosed.