Coil Component Resin Coating for Dielectric Strength
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Solution Overview
Problem
Coil components using thin-diameter coated conductive wires face insufficient dielectric strength voltage due to degradation of the coating film during wire connection processes like thermo-compression bonding or laser bonding, which compromises the insulation between primary and secondary windings.
Innovation Solution
A coil component design featuring a drum core with flange portions and a winding core, where a coated conductive wire is wound and connected using thermo-compression or laser bonding, with a resin coating layer applied to cover the wire in the winding core portion to enhance dielectric strength, and a plate core bonded to the flange portions to form a closed magnetic circuit, preventing resin coating on wire connection areas to maintain solder wettability and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a thin-diameter coated conductive wire is used to reduce component size, then the component size is reduced, but the dielectric strength voltage becomes insufficient due to coating film degradation during wire connection
Solution Approach 1:
A resin coating layer is formed on the coated conductive wire before the wire connection process. This preliminary protective layer prevents heat from the subsequent wire connection process (thermo-compression bonding or laser bonding) from degrading the coating film, thereby maintaining dielectric strength voltage despite using thin-diameter wires for size reduction
Solution Approach 2:
The resin coating layer acts as a cushioning protective layer that absorbs and isolates the thermal stress during wire connection. This beforehand cushioning prevents the coating film from direct heat exposure, preserving its insulating properties and preventing dielectric breakdown even when using thinner wires
2Reliability
If a resin coating layer is applied to cover the coated conductive wire to improve dielectric strength voltage, then dielectric strength voltage is improved, but the wire connection portions may be affected by resin coating
Solution Approach 1:
The resin coating layer is selectively applied only to specific portions of the coated conductive wire - specifically covering the winding core portion while excluding the wire connection portions (terminal ends). This local quality approach ensures dielectric protection where needed while maintaining solder wettability and connection quality at the terminal ends
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 resin coating layer effectively improves dielectric strength voltage while maintaining high magnetic properties and preventing connection failures, even with thin-diameter wires, by covering the coated conductive wire in the winding core portion and avoiding resin coating on wire connections.
Implementation Method 1
forming a resin coating layer to cover at least the coated conductive wire that is located in a first layer in the winding core portion by melting the resin film
Implementation Method 2
heat that is applied at the time of wire connection is conveyed via core material of the coated conductive wire
Data Source
AI summary
Disclosed herein is a coil component that includes: a drum core that includes first and second flange portions having wire connection portions and a winding core portion located between the first and second flange portions; a coated conductive wire that is wound around the winding core portion, each end of the coated conductive wire being connected to respective one of the wire connection portions; and a resin coating layer that covers at least the coated conductive wire located in a first layer in the winding core portion.