Resin-Supported Block Coil With Gapped Core for Terminal Stability
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Solution Overview
Problem
Existing block coils lack structural support for terminals, leading to risks of short circuits and terminal displacement, and there is a need to enhance power handling capability by preventing core saturation.
Innovation Solution
The block coils are integrated with a resin body that supports terminals, and the magnetic core includes gaps to enhance power handling capability by delaying core saturation, while ensuring terminal stability and reducing short circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If terminals are extended over the magnetic core without support structure, then the block coil can be simpler in structure, but the terminals risk short circuiting or falling sideways
Solution Approach 1:
The patent introduces a support structure as an intermediary element between the terminals and the magnetic core. This support structure provides mechanical stabilization for the terminals, preventing them from falling sideways or short circuiting, while not significantly increasing the overall complexity of the block coil assembly.
2Power
If the magnetic core includes gaps, then the power handling capability is enhanced by delaying core saturation, but the magnetic core structure becomes more complex
Solution Approach 1:
The patent applies segmentation by introducing gaps that divide the magnetic core into separate sections. These gaps prevent continuous magnetic flux paths, thereby delaying core saturation and enhancing power handling capability. The segmented structure achieves improved performance while maintaining reasonable structural complexity.
3Reliability
If terminals are embedded in resin body, then terminal support and short circuit prevention are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the terminal support function with the resin body by embedding terminals directly into the resin structure. This integration provides mechanical support and electrical insulation simultaneously, improving reliability while the molding process incorporates these features without requiring separate manufacturing steps.
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 solution provides enhanced terminal support, reduces short circuit risks, and improves power handling capacity by controlling core saturation, thereby ensuring reliable operation and efficient performance.
Implementation Method 1
The one or more gaps increase the power handling capability of the magnetic core by delaying core saturation
Data Source
AI summary
An electronic module includes a substrate or a lead frame including a primary conductive pattern and a secondary conductive pattern; a magnetic core that is located on or above the substrate or the lead frame and that includes a gap; a block coil including a resin body that is located on or above the substrate or the lead frame and that extends over the magnetic core, a first terminal that is on or embedded in the resin body and that is connected to the primary conductive pattern, and a second terminal that is on or embedded in the resin body and that is connected to the secondary conductive pattern; and an electronic component located on the substrate or the lead frame.