Layered Block Coil Structure for Terminal Isolation
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Solution Overview
Problem
Existing block coils lack structural support for terminals, leading to a risk of short circuits and terminal displacement.
Innovation Solution
Incorporating a resin body with terminals embedded in different layers within the resin body, providing structural support and reducing the risk of short circuits and terminal displacement, while enhancing power handling capability through magnetic core gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If terminals are extended over the magnetic core without support structure, then the block coil can be manufactured with simpler structure, but the terminals risk short circuiting or falling sideways
Solution Approach 1:
The patent introduces a support structure as an intermediary element between the terminals and the magnetic core. This support structure provides mechanical stabilization for the terminals while maintaining electrical isolation, thus preventing short circuits and terminal displacement without significantly complicating the overall block coil structure.
Solution Approach 2:
The block coil is divided into distinct functional segments: the magnetic core, the support structure, and the terminals. This segmentation allows each component to perform its specific function independently - the support structure provides mechanical stability while the terminals provide electrical connection, resolving the contradiction between simplicity and reliability.
2Power
If magnetic core gaps are added to delay core saturation, then power handling capability is improved, but the device structure becomes more complex
Solution Approach 1:
The patent modifies the magnetic core by introducing gaps, which changes the magnetic path parameters. This parameter change delays core saturation and improves power handling capability. The gaps are strategically positioned to achieve the desired magnetic flux distribution while minimizing structural complexity.
3Reliability
If terminals are arranged in different layers within the resin body, then short circuit risk is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent transitions from planar terminal arrangement to three-dimensional layered arrangement within the resin body. By utilizing the vertical dimension, terminals are separated into different layers, which effectively prevents short circuits while allowing for standardized manufacturing processes that can handle multi-layer configurations.
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
The solution effectively prevents short circuits and terminal displacement, improves power handling capability by delaying core saturation, and allows for versatile terminal arrangements without additional design costs.
Implementation Method 1
The one or more gaps increase the power handling capability of the magnetic core by delaying core saturation
Data Source
AI summary
An electronic module includes a substrate or a lead frame including a primary conductive pattern and a secondary conductive pattern; a magnetic core located on or above the substrate or the lead frame; a block coil including a resin body that is located on or above the substrate or the lead frame and that extends over the magnetic core, a first terminal that is on or embedded in the resin body in a first layer and that is connected to the primary conductive pattern, and a second terminal that is on or embedded in the resin body in a second layer different from the first layer and that is connected to the secondary conductive pattern; and an electronic component located on the substrate or the lead frame.