Insulation Frame Coil Structure for Miniaturized Magnetic Components
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Solution Overview
Problem
The existing coil components lack sufficient insulation performance between terminals and cores, which affects their reliability and miniaturization potential.
Innovation Solution
A coil component design featuring a magnetic core housed within an insulation frame, with an electrode terminal member on the insulation frame and coils made of insulatingly coated lead wire wound around the frame and core, ensuring effective insulation between the terminal, core, and coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are provided directly on the core structure, then device complexity is reduced, but insulation performance between terminals and core deteriorates
Solution Approach 1:
An insulation frame is introduced as an intermediary component between the core and the terminal. The insulation frame houses the core and provides an insulating barrier, while the terminal is mounted on the insulation frame rather than directly on the core. This mediator structure ensures reliable insulation between the conductive terminal and the magnetic core without requiring complex additional insulation measures.
2Reliability
If insulation measures are enhanced between terminal and core, then reliability improves, but device complexity increases
Solution Approach 1:
The insulation frame serves multiple functions simultaneously: it houses the core to provide mechanical support and positioning, it provides the necessary insulation between the core and terminal, and it serves as the mounting structure for the terminal. By making the insulation frame multi-functional, the design achieves reliable insulation without adding separate complex insulation components or structures.
3Productivity
If component size is reduced for miniaturization, then productivity improves, but insulation performance may deteriorate
Solution Approach 1:
The core is nested within the insulation frame, with the terminal mounted on the outer surface of the insulation frame. This nested arrangement allows compact positioning of components while maintaining the insulating barrier. The insulation frame acts as a containing structure that enables miniaturization by efficiently organizing components in a compact configuration while preserving the necessary insulation distance between the core and terminal.
Data Source
AI summary
A coil component includes a magnetic core having a core portion; an insulation frame housing the magnetic core; an electrode terminal member provided on the insulation frame; and at least one coil, which is formed of an insulatingly coated lead wire and is electrically connected to the electrode terminal member, wherein at least one coil includes a winding portion wound around the insulation frame and the core portion so as to be in contact with a second wall portion and a fifth wall portion of the insulation frame.