Resin-Supported Block Coil Terminals to Prevent Short Circuits
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Solution Overview
Problem
Existing block coils lack structural support for their terminals, leading to a risk of short circuits and terminal displacement.
Innovation Solution
Incorporating a resin body to house the terminals, providing structural support and reducing the risk of short circuits and terminal displacement.
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 manufactured with simpler 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 prevents direct contact between terminals from opposite sides, eliminating the short circuit risk while providing mechanical support to prevent terminal displacement. The support structure acts as a mediator that resolves the conflict between simple manufacturing and terminal reliability.
2Ease of manufacture
If no support structure is provided for terminals, then the manufacturing process is simpler, but the terminals may fall sideways or short circuit
Solution Approach 1:
The patent merges the support structure with the magnetic core or the block coil housing, creating an integrated assembly. This integration maintains manufacturing simplicity by combining multiple functions into a single component while providing the necessary terminal support. The merged structure eliminates the need for separate support elements, thus maintaining ease of manufacture while improving terminal reliability.
3Volume of moving object
If terminals are positioned close to each other for compact design, then the block coil size is reduced, but the risk of short circuit increases
Solution Approach 1:
The support structure serves as a physical intermediary that maintains safe spacing between terminals from opposite sides. Even when the block coil is designed for compactness, the support structure ensures that terminals do not come into direct contact, thus preventing short circuits while allowing the overall device volume to be minimized.
Data Source
AI summary
An electronic module includes a substrate or a lead frame including primary conductive patterns and secondary conductive patterns; a magnetic core; 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, first terminals that define a first terminal group and that are on or embedded in the resin body, and second terminals that define a second terminal group and that on or are embedded in the resin body; an IC; and a capacitor. Two first terminals of the first terminal group are connected to corresponding primary conductive patterns; two second terminals of the second terminal group are connected corresponding secondary conductive patterns; and a first primary conductive pattern is closer to a second primary conductive pattern than any of the secondary conductive patterns.