Coil Component Dual Resin Substrate High Voltage Isolation
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Solution Overview
Problem
Coil components with metal magnetic grains in resin substrates have lower insulation properties compared to those with ferrite grains, and are prone to shorting when high voltage is applied, especially when terminal parts are embedded in the resin, leading to surface or internal discharge.
Innovation Solution
A coil component design featuring a substrate body with two resin parts, one with higher insulation properties than the other, where the coil is embedded in the lower insulation resin part and the terminal parts are connected to a higher insulation resin part, preventing shorting by ensuring the higher insulation resin part is between the terminal parts and the lower insulation part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal magnetic grains are used in the resin substrate, then the coil component achieves better magnetic performance, but the insulation property of the substrate body deteriorates
Solution Approach 1:
The substrate body is divided into two distinct resin parts: a first resin part containing metal magnetic grains for magnetic performance, and a second resin part with higher insulation properties for electrical isolation. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the substrate body are assigned different material properties: the first resin part (with metal magnetic grains) provides magnetic performance where needed, while the second resin part provides enhanced insulation properties in areas requiring electrical isolation, particularly between terminal parts.
2Device complexity
If terminal parts are embedded in the resin substrate, then the device structure is simplified, but shorting occurs under high voltage conditions
Solution Approach 1:
The substrate is segmented into two resin parts where the second resin part with higher insulation properties is positioned between terminal parts, providing electrical isolation while maintaining the embedded terminal structure.
Solution Approach 2:
The second resin part acts as an intermediary material with high insulation properties, placed between terminal parts to prevent electrical discharge and shorting under high voltage conditions, while still allowing the terminals to be embedded in the substrate.
3Power
If high voltage is applied between terminals, then the coil component can handle higher power, but surface or internal discharge occurs
Solution Approach 1:
The second resin part serves as an intermediary with superior insulation properties, positioned between terminal parts to withstand high voltage stresses and prevent electrical discharge, enabling the coil component to handle higher power without surface or internal discharge.
Solution Approach 2:
The substrate body uses a composite structure of two different resin materials: the first resin part provides magnetic properties, while the second resin part provides high voltage insulation, creating a composite material system that handles both magnetic performance and high voltage requirements.
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
Prevents shorting between terminal parts even under high voltage conditions by utilizing a higher insulation resin part to isolate the terminal connections, maintaining effective coil characteristics while enhancing insulation properties.
Implementation Method 1
a coil embedded in the first resin part and formed by a conductor having an insulating film
Implementation Method 2
a second resin part joined to the surface of the first resin part and formed by a material that contains resin, and whose insulation property is higher than that of the first resin part
Data Source
AI summary
A coil component includes: a substrate body having a first resin part formed by a resin that contains magnetic grains, and a second resin part joined to the surface of the first resin part and formed by a material that contains resin, and whose insulation property is higher than that of the first resin part; a coil embedded in the first resin part and formed by a conductor having an insulating film; leader parts formed by the conductor and led out from the coil to the second resin part; and terminal parts connected electrically to the leader parts; wherein covered parts of the leader parts, which are covered with the insulating film, are embedded partially in the second resin part, and the second resin part is disposed between the terminal parts and the first resin part, thereby preventing shorting between the terminal parts.