Coil Component Insulation Design for Withstand Voltage
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Solution Overview
Problem
Conventional coil components, such as those described in Japanese Patent Publication Number H08-213242, have inadequate withstand voltage performance between the terminal and core, indicating a need for improved insulation and structural reinforcement.
Innovation Solution
A coil component design featuring a core member with parallel shafts and opposed members, supported by an insulating case with outer walls, where the coil is wound around the shafts and metal terminals are connected to the outer walls, ensuring sufficient insulation distance and structural integrity between the terminal and core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal and core are positioned close to each other for compact design, then the device size is reduced, but the withstand voltage performance deteriorates
Solution Approach 1:
An insulating case is introduced as an intermediary component between the terminal and the core member. The case includes an insulating outer wall that physically separates these conductive elements, ensuring adequate insulation distance and withstand voltage performance while allowing the overall device to maintain a compact form factor.
Solution Approach 2:
The insulating case provides localized insulation specifically where needed - between the terminal and core member - rather than requiring uniform insulation throughout the entire device. This allows compact dimensions in non-critical areas while maintaining sufficient insulation distance in the critical gap between conductive elements.
2Reliability
If insulation distance between terminal and core is increased for better withstand voltage, then breakdown strength is improved, but the structural complexity increases
Solution Approach 1:
The insulating case serves multiple functions simultaneously: it provides electrical insulation between the terminal and core member, supports the core member in a fixed position, and defines the overall device housing. By combining insulation, support, and housing functions into a single integrated component, the design achieves adequate breakdown strength without proportionally increasing structural complexity.
Solution Approach 2:
The insulating case is designed as a multi-functional component that performs insulation, mechanical support, and structural housing functions. This universal component approach allows the device to achieve improved withstand voltage performance through a single element rather than requiring multiple separate components for each function.
Data Source
AI summary
A coil component includes: a core having first and second shafts arranged in a line, and first and second opposed members; a case supporting the core and having a housing accommodating the core, and first and second outer walls opposing each other; a coil wound around the first and second shafts; and first and second metal terminals being electrically connected to the coil and being provided at the first and second outer walls, respectively. The first and second opposed members are opposed to each other and sandwich the first and second shafts therebetween.