Ribbed Molded Body Structure for High-Voltage Creepage Insulation
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Solution Overview
Problem
Existing electrical components with flat molded bodies are inadequate for high voltage applications, as they do not provide sufficient insulation and creepage distance, leading to potential performance degradation and safety issues under high voltage conditions.
Innovation Solution
The development of an electrical component with a ribbed molded body, featuring a plurality of ribs along its surface, which increases the creepage distance and enhances insulation, allowing for higher voltage applications by using a mold compound with a comparative tracking index (CTI) of 600V, thereby meeting stricter voltage rating requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat molded body is used, then the device complexity is low and manufacturing is easy, but the insulation performance and creepage distance are insufficient for high voltage applications
Solution Approach 1:
The patent applies curvature by transitioning from a flat molded body surface to a ribbed surface with multiple raised ridges. These ribs create a three-dimensional textured structure that increases the surface path length between electrical leads, thereby enhancing creepage distance and insulation performance without fundamentally changing the basic package geometry
Solution Approach 2:
The invention adds dimensional complexity by introducing ribs that protrude from the flat surface, creating a multi-level topography. This dimensional change transforms the two-dimensional flat surface into a three-dimensional ribbed structure, effectively increasing the electrical creepage path while maintaining a compact overall package size
2Length of stationary object
If a flat molded body is used, then the manufacturing process is simple, but the creepage distance between leads is insufficient
Solution Approach 1:
The molded body surface is segmented into multiple rib structures that divide and extend the electrical creepage path. Instead of a single flat surface, the ribs create multiple segments that force the electrical discharge to follow a longer, more tortuous path, effectively increasing creepage distance through geometric segmentation rather than simply enlarging the overall package
3Reliability
If a ribbed molded body is implemented, then the insulation and creepage distance are enhanced, but the device structure becomes more complex
Solution Approach 1:
The ribbed structure is applied locally to specific regions of the molded body where creepage enhancement is most needed, rather than uniformly across the entire surface. This localized application of geometric complexity allows the design to maintain simplicity in areas where it is not required while providing enhanced insulation performance where high voltage stress occurs
Data Source
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AI summary
An electrical device comprising a ribbed molded body housing an electrical component is provided. The ribbed molded body includes at least one surface or portion having a plurality of ribs along at least a portion of the surface. The electrical component may be a passive or active electrical component. The electrical component may be connected to a lead frame and molded into the ribbed molded body.