Flat-Wire Inductor Insulation Structure for Recess Withstand
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Solution Overview
Problem
The existing manufacturing process for inductors with a coil conductor and magnetic particles results in reduced insulation at recesses, compromising the withstand performance due to the thinner insulation coating at the corners of the flat rectangular conductive wire.
Innovation Solution
A band-shaped conductive wire with an insulating layer and a fusion layer is wound to form a coil conductor, where recesses in the wound section are partially filled with a resin from the fusion layer, enhancing insulation between the coil conductor and magnetic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat rectangular conductive wire with insulation coating is used to form the coil conductor, then the manufacturing process is simplified and the coil structure is easy to form, but the insulation at the recesses (especially at corners) is reduced, compromising the withstand performance
Solution Approach 1:
The patent applies local quality by providing different insulation structures at different locations of the coil conductor. Specifically, the corners of the flat rectangular conductive wire are provided with additional corner insulation layers or thicker insulation coating compared to other regions. This local enhancement of insulation quality at the recesses (where corners are positioned deep) resolves the contradiction by maintaining easy manufacturing of the flat wire structure while improving withstand performance at the critical recess locations where insulation was previously reduced.
2Ease of manufacture
If the insulation coating is made thinner to reduce material cost and simplify manufacturing, then the manufacturing process becomes easier and material usage is reduced, but the insulation between the coil conductor and magnetic particles is insufficient, reducing the withstand performance
Solution Approach 1:
The patent implements local quality by applying non-uniform insulation coating thickness to the flat rectangular conductive wire. The insulation coating is made thicker at the corners and recess regions while maintaining thinner insulation at other areas. This localized insulation enhancement ensures that the critical regions (recesses) have sufficient insulation for withstanding high voltage, while the overall manufacturing process and material usage remain efficient.
Solution Approach 2:
The patent applies preliminary action by pre-forming the insulation coating with variable thickness on the conductive wire before winding it into the coil structure. The insulation coating is applied with thicker regions at corners and recess areas during the wire preparation stage, so that when the wire is wound and recesses are formed, the insulation is already in place at the critical locations, eliminating the need for post-processing insulation enhancement.
Data Source
AI summary
An inductor includes a base body including a coil conductor and a core in which the coil conductor is embedded. The coil conductor includes a wound band-shaped conductive wire, and the core contains magnetic particles and a resin. The band-shaped conductive wire has a cross-sectional shape including principal faces that are parallel to each other and end faces that connect the principal faces to each other. The coil conductor is formed by winding the band-shaped conductive wire having a covering layer including an insulating layer and a fusion layer. The insulating layer covers a surface of the band-shaped conductive wire. The fusion layer covers the insulating layer. A recess defined by the insulating layer is in an end face of a wound section, in which the band-shaped conductive wire is wound, in an axial direction, and is at least partially filled with a resin of the fusion layer.