Coil Terminal Structure for Creepage Distance in Compact Assemblies
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Solution Overview
Problem
Existing coil devices face challenges in achieving both miniaturization and reliable insulation between the core and terminal or winding portion and lead portion, as extending the terminal installation portion to ensure creepage distance compromises the compactness and low profile of the device.
Innovation Solution
Incorporating a convex portion on the terminal installation portion to separate the core and terminal, and a cover member between the winding and lead portions to extend the insulation distance, allowing for a compact design with enhanced insulation reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal installation portion is extended to ensure creepage distance between core and terminal, then insulation reliability is improved, but device size increases
Solution Approach 1:
The patent introduces a convex portion that protrudes in the radial direction (third direction) from the terminal installation portion, transforming the insulation distance extension from an axial dimension issue to a radial dimension solution. This allows the creepage distance to be increased without extending the axial length of the terminal installation portion, thereby maintaining device compactness while improving insulation reliability between the core and terminal.
2Reliability
If the distance between winding portion and lead portion is increased to ensure insulation, then insulation reliability is improved, but device profile increases
Solution Approach 1:
The patent introduces a cover member as an intermediary component disposed between the winding portion and the lead portion. This cover member physically separates these two components, ensuring adequate insulation distance and preventing direct contact or close proximity that would compromise insulation reliability. The cover member acts as a mediator that maintains the required clearance without necessitating an increased overall device profile.
Data Source
AI summary
A coil device includes a coil, a terminal, a bobbin, and a core. The coil includes a winding portion and a lead portion drawn out from the winding portion. The terminal is connected with the lead portion. The bobbin includes a cylinder portion for the winding portion and a terminal installation portion formed at an end in a first direction parallel to an axial direction of the cylinder portion and provided with the terminal. The core is attachable to the bobbin. The terminal installation portion includes a convex portion separating the core and the terminal.