Isolator Lead Layout to Prevent Substrate Misalignment
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Solution Overview
Problem
Existing isolators face challenges with defects such as rotation or misalignment of the substrate, which can lead to electrical connection defects like shorts or opens.
Innovation Solution
The isolator design includes a substrate with multiple coils and conductive parts, where leads are connected to terminal portions on the substrate using solder, ensuring secure attachment and minimizing the risk of rotation or misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If leads are connected to terminal portions on the substrate using solder, then connection strength is improved, but the risk of substrate rotation or misalignment during soldering increases
Solution Approach 1:
The patent applies preliminary anti-action by designing the substrate with a quadrilateral lower surface and positioning terminal portions at specific corners to preemptively counteract rotation forces during soldering. The symmetric corner positioning creates balanced solder joint distribution that prevents rotational movement before it can occur, addressing the alignment issue proactively rather than reactively.
Solution Approach 2:
The patent implements preliminary action by pre-positioning terminal portions at the corners of the quadrilateral lower surface before the soldering process begins. This predetermined geometric configuration ensures that when solder is applied to connect leads, the forces are distributed symmetrically to maintain alignment, preventing misalignment before it happens.
2Reliability
If multiple leads are connected to the substrate, then electrical connection reliability is improved, but the complexity of ensuring proper alignment and avoiding defects increases
Solution Approach 1:
The patent applies segmentation by dividing the connection structure into distinct geometric zones: a quadrilateral lower surface with terminal portions positioned at four separate corners. This segmentation creates independent connection points that are easier to control and align individually, reducing the overall complexity of ensuring proper alignment for multiple leads while maintaining high reliability.
Solution Approach 2:
The patent utilizes asymmetry in a controlled manner by employing a quadrilateral (rectangular) lower surface rather than a circular or symmetric shape. This asymmetric geometry provides distinct corner positions for terminal portions, creating natural reference points that simplify alignment control during manufacturing while enabling multiple reliable electrical connections.
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
This design effectively suppresses electrical defects and enhances the reliability of the isolator by ensuring stable connections and preventing substrate misalignment during the soldering process.
Implementation Method 1
leads are connected to terminal portions on the substrate using solder
Data Source
AI summary
An isolator according to one embodiment, includes a substrate and a plurality of leads. The substrate includes a lower surface, a plurality of coils, and a plurality of conductive parts. The lower surface has a quadrilateral shape. The plurality of coils includes a first coil, and a second coil. The plurality of conductive parts includes a first conductive part, a second conductive part, a third conductive part, and a fourth conductive part. The first conductive part includes a first terminal. The second conductive part includes a second terminal. The third conductive part includes a third terminal. The fourth conductive part includes a fourth terminal. The plurality of leads includes a first lead, a second lead, a third lead, and a fourth lead. The plurality of leads includes a metal.