Coil Component Urethane Coat Regions for Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The thermocompression bonding process for coil components can lead to electrical shortings and insufficient insulation due to the removal of the resin coat, exposing the central conductor, and the remaining coat is susceptible to hydrolysis and potential differences, causing reliability issues over time.
Innovation Solution
The coil component design incorporates a coat with a first region containing a urethane group for the connection points and a second region without a urethane group for the extending portions, ensuring reliable connections and preventing coat modification and potential differences between the wires, thereby reducing electrical shortings and insulation issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermocompression bonding process is used to connect wires to terminal electrodes, then reliable electrical connection is achieved, but the resin coat is removed exposing the central conductor causing electrical shortings and insufficient insulation
Solution Approach 1:
The patent applies local quality by creating different coat regions with different properties: a first region without urethane groups at the connection portion for reliable bonding, and a second region with urethane groups at the extending portion for maintained insulation. This localized differentiation resolves the contradiction between connection reliability and insulation prevention.
Solution Approach 2:
The resin coat is segmented into functionally distinct regions: the first region (connection portion) undergoes coat removal for electrical connection, while the second region (extending portion) maintains coat integrity for insulation. This segmentation allows each region to fulfill its specific function without compromising the other.
2Manufacturing precision
If high temperature is applied during thermocompression bonding, then appropriate connection between central conductor and terminal electrode is achieved, but the resin coat is removed at portions beyond the connection point exposing central conductor
Solution Approach 1:
The patent uses local quality by designing the resin coat with spatially varying chemical composition: the first region lacks urethane groups making it susceptible to heat-induced removal for precise connection, while the second region contains urethane groups that resist heat and maintain insulation. This enables precise control of coat removal location during thermocompression bonding.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition parameter of the resin coat across different regions. The absence or presence of urethane groups creates different thermal response characteristics, allowing the coat to be selectively removed only where needed during the bonding process while maintaining integrity elsewhere.
3Object-affected harmful factors
If the resin coat remains in the wire extending portion, then insulation is maintained, but the coat may be modified by voltage and moisture causing hydrolysis and deteriorated dielectric strength over time
Solution Approach 1:
The patent applies local quality by endowing the resin coat with different chemical compositions in different regions: the second region contains urethane groups that provide resistance to hydrolysis and maintain long-term electrical stability, while the first region lacks these groups to facilitate initial connection. This localized chemical differentiation resolves the contradiction between insulation protection and long-term reliability.
Solution Approach 2:
The patent uses composite materials by creating a resin coat with heterogeneous composition - combining regions with and without urethane groups. This composite structure allows the coat to simultaneously provide insulation protection where needed while maintaining long-term stability in regions exposed to voltage and moisture, resolving the contradiction between these two 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
This configuration ensures reliable connections and prevents electrical shortings and insulation issues in the coil component, even in areas where the coat remains, by maintaining the urethane group in the first region and modifying it in the second region, thus enhancing the component's reliability and durability.
Implementation Method 1
the coat in the wire is removed by heat produced by the heater chip
Data Source
AI summary
A coil component includes a drum core and first and second wires. The first wire includes a first extending portion. The second wire includes a third extending portion. The first and third extending portions are not in contact with each other. Each of the first and second wires includes a coat including a first region and a second region. The coat in the first and third extending portions is the second region at least in part. The coat is the first region at a contacting point where the first and second wires are in contact for the first time from a first flange portion in the drum core.