Integrated Coil Holder Partitions for High-Voltage Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components, such as common-mode choke coils, face inadequate insulation and insufficient withstand voltage performance due to gaps between partition elements, which is exacerbated by increasing driving voltages in electric vehicle power supply circuits.
Innovation Solution
A coil component design featuring a frame-shaped magnetic core with integrally formed partitions surrounding cylindrically wound coil conductors, ensuring no gaps for enhanced insulation and using a ferrite-based magnetic core with a fastening unit for improved adhesion and noise reduction, along with rectangular wire for increased rated current capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If partition elements are assembled separately into the casing, then the device complexity is reduced and ease of manufacture is improved, but gaps are created between partition elements and the casing, worsening the insulation performance
Solution Approach 1:
The partition elements and the casing are merged into a single integrally formed insulating housing. This integration eliminates the gaps that would exist between separately assembled partition elements and the casing, ensuring continuous insulation without compromising the ease of manufacture through complex assembly processes.
2Volume of moving object
If the coil component is miniaturized, then the volume is reduced for compact design, but the insulation distance between coil conductors is reduced, worsening the withstand voltage performance
Solution Approach 1:
The insulating housing provides localized insulation enhancement at critical areas where high voltage stress occurs, such as between the coil conductors and the magnetic core. By concentrating insulation material where it is most needed rather than uniformly throughout, the design maintains adequate insulation distances even in a miniaturized configuration, ensuring withstand voltage performance is not compromised by reduced overall volume.
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 design achieves sufficient insulation and high withstand voltage performance, enabling effective noise reduction and improved substrate mountability while supporting increased current ratings.
Implementation Method 1
a frame-shaped magnetic core (1) including wound sections (5a, 5b) facing each other, a pair of coil conductors (3a, 3b) in which a wire (2) is cylindrically wound
Implementation Method 2
using a ferrite-based magnetic core
Data Source
AI summary
A coil component includes a frame-shaped magnetic core including wound sections facing each other, cylindrical coil conductors, and a holder made of an insulating material and holding the coil conductors and the magnetic core. The magnetic core extends through the coil conductors such that the coil conductors and the wound sections are associated with each other. The holder includes a first partition disposed between the magnetic core and a first winding wire end of each of the coil conductors, a second partition disposed between the magnetic core and a second winding wire end of each of the coil conductors, and a third partition disposed between the coil conductors. The first to third partitions are integrally formed.