Coil Structure Insulating Member Positioning
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Solution Overview
Problem
Conventional coil structures face challenges in reducing size while maintaining performance, particularly due to difficulties in precise positioning and heat dissipation.
Innovation Solution
The coil structure incorporates an insulating member with side wall parts that adjust the distance between cores and the coil conductor, allowing for easier positioning and reduced size, while also utilizing a heat dissipation material in gaps between cores to enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating member is disposed between the foot parts and the coil conductor to secure insulating distance, then safety insulation is improved, but the overall size of the coil structure increases
Solution Approach 1:
The insulating member combines multiple functions into a single component: it provides insulation between the foot parts and coil conductor, positions the first core relative to the second core, and maintains the gap between cores. This integration eliminates the need for separate insulating components, achieving safety insulation while minimizing overall size.
Solution Approach 2:
The insulating member serves multiple purposes simultaneously: electrical insulation, mechanical positioning, and gap maintenance. By making the insulating member multi-functional, the design achieves reliable insulation distances without adding extra components that would increase the overall volume of the coil structure.
2Ease of manufacture
If the gap between the first foot part and the second core is increased to facilitate positioning and checking of the insulating member, then ease of manufacture is improved, but the magnetic coupling between cores deteriorates
Solution Approach 1:
The insulating member acts as an intermediary element that defines and maintains the optimal gap distance between the first foot part and the second core. It provides physical reference surfaces for positioning during assembly, making it easy to check and manufacture, while simultaneously maintaining the gap at a size that preserves adequate magnetic coupling through the core assembly.
3Volume of moving object
If the distance between the foot parts and the coil conductor is reduced to decrease overall size, then volume is reduced, but electrical insulation safety deteriorates
Solution Approach 1:
The insulating member integrates insulation, positioning, and gap maintenance functions, allowing the foot parts to be positioned closer to the coil conductor while maintaining adequate insulation distance through the insulating member's structure.
Solution Approach 2:
The insulating member extends in multiple dimensions to provide insulation in critical areas while allowing compact overall dimensions. By strategically positioning insulating walls and surfaces in three-dimensional space, adequate insulation is achieved without increasing the overall envelope size of the coil structure.
Data Source
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AI summary
The first core includes a main body part extending in a first direction along a main surface of the substrate, a first foot part extending from the main body part to the second core through the substrate, and a second foot part extending from the main body part to the second core through the substrate at a position at which the coil conductor is sandwiched between itself and the first foot part in the first direction, and the insulating member includes a bottom wall part interposed between at least the first foot part and the second core, and a side wall part extending along at least either of the first foot part and the second foot part and interposed between either of the foot parts and the coil conductor.