Block Coil Resin Body Structure for Terminal Stability and Isolation
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Solution Overview
Problem
Existing block coils lack support for their terminals, leading to a risk of short circuits and terminal fall, as there is no structure to prevent these issues.
Innovation Solution
Incorporating a resin body with embedded or surface-mounted terminals that connect to conductive patterns on a substrate or lead frame, providing structural support and reducing the risk of short circuits and terminal fall.
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 simpler in structure, but the risk of short circuit and terminal fall increases
Solution Approach 1:
The patent introduces a support structure as an intermediary element between the terminals and the magnetic core/substrate. This support structure serves as a mediator that provides mechanical support to the terminals while maintaining electrical isolation, thus preventing both short circuits and terminal fall without significantly complicating the overall block coil structure.
Solution Approach 2:
The support structure is formed using composite materials that combine mechanical support properties with electrical insulation properties. This allows the single support structure to simultaneously prevent terminal fall (mechanical function) and short circuits (electrical function), resolving the contradiction between simplicity and reliability.
2Ease of manufacture
If no support structure is used for terminals, then the block coil manufacturing process is simpler, but the risk of terminal fall and short circuit increases
Solution Approach 1:
The patent merges the support function and insulation function into a single integrated support structure. This consolidation means that while the structure itself is added, multiple functions are achieved simultaneously, and the overall manufacturing process remains relatively simple without requiring separate support components and insulation components to be assembled separately.
Solution Approach 2:
The support structure acts as an intermediary element that can be integrated into the existing manufacturing flow. It provides the necessary mechanical and electrical functions during assembly and operation, enabling reliable terminal support without fundamentally changing the manufacturing complexity.
Data Source
AI summary
A magnetic component includes a substrate or a lead frame including a primary conductive pattern and a secondary conductive pattern; a magnetic core located on or above of 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 and that is connected to the primary conductive pattern, and a second terminal on or embedded in the resin body and that is connected to the secondary conductive pattern; and an insulating material covering the substrate or the lead frame, the magnetic core, and the block coil.