Coil Device Segmented Base Curved Edges
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Solution Overview
Problem
Existing coil devices face issues with short circuits due to damage to the insulation coating of the coil, leading to contact between the conductor portion and the terminal, and require unnecessary bending of the lead portion to connect with the wire connecting portion, increasing man-hours and reducing quality.
Innovation Solution
A coil device design where the base portion is positioned at the same height as the coil's bottom surface, with curved main and sub-branch portions that do not physically contact the coil, allowing the lead portion to be connected without bending, thus preventing short circuits and improving quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the coil is disposed on the upper surface of the base portion, then the coil can be prevented from being displaced during compression molding, but the conductor portion of the coil may come into contact with the terminal causing a short circuit
Solution Approach 1:
The base portion is divided into a main branch portion and a sub branch portion, creating a segmented structure that provides both support for coil positioning and electrical insulation. The segmentation allows the base portion to fulfill multiple functions: holding the wire connecting portion stable during molding while maintaining safe distance from the coil conductor to prevent short circuits.
2Reliability
If the coil is disposed at a position spaced upward from the upper surface of the base portion, then physical contact between the base portion and the coil is avoided, but the lead portion requires bending processing increasing man-hours
Solution Approach 1:
The base portion is positioned at substantially the same height as the bottom surface of the coil, creating an equipotential arrangement in terms of vertical positioning. This eliminates the height difference that would require lead portion bending, allowing direct connection while maintaining safe horizontal spacing through the curved inner edges to prevent short circuits.
3Volume of moving object
If the inner edges of the base portion are positioned close to the outer peripheral surface of the coil, then the structure becomes compact, but the withstand voltage between the base portion and coil is reduced
Solution Approach 1:
The inner edges of the main branch portion and sub branch portion are formed with curved portions that follow the curvature of the coil's outer peripheral surface. This curved design allows the base portion to approach closer to the coil, achieving compactness, while the curved geometry maintains adequate clearance and electrical insulation, ensuring sufficient withstand voltage between the base portion and the coil conductor.
Data Source
AI summary
An inductor includes a coil; terminals including wire connecting portions connected to lead portions of the coil, and base portions positioned at substantially the same height as a bottom surface of the coil and holding the wire connecting portions; and a core covering the coil together with the wire connecting portions and the base portions. The base portions include main branch portions and sub branch portions. Inner edges of the main branch portions are formed with curved portions curved along an outer peripheral surface of the coil at positions separated from the outer peripheral surface of the coil, respectively. Inner edges of the sub branch portions are formed with curved portions curved along the outer peripheral surface of the coil at positions separated from the outer peripheral surface of the coil, respectively.