Slim Magnetic Component Terminal Layout for Coil Short Prevention
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Solution Overview
Problem
Conventional slim-type magnetic components face challenges such as interference or shorts between secondary coils due to their reduced size, which complicates automated winding and increases production costs and material losses.
Innovation Solution
The proposed slim-type magnetic component features a core unit with a bobbin unit that includes separate terminal accommodation portions for primary and secondary coils, allowing for non-overlapping terminal pin placement and enabling automated winding without risking coil interference or shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of magnetic components is reduced to meet slim form factor requirements, then the component achieves a compact size, but interference or shorts between secondary coils occur easily
Solution Approach 1:
The patent transitions from a conventional single-layer terminal pin arrangement to a multi-dimensional layout where terminal pins are arranged in multiple layers (first layer and second layer) on the bobbin. This spatial redistribution in the vertical dimension allows coil extension portions to be routed through different layers, preventing interference and shorts while maintaining compact component size.
2Device complexity
If terminal pins are arranged in a single layer with coil end portions intersecting, then the component structure is simplified, but interference or shorts between coils occur during soldering
Solution Approach 1:
The patent segments the terminal pin arrangement into multiple layers (first layer and second layer) instead of using a single layer. This segmentation spatially separates coil extension portions that would otherwise intersect, preventing interference and shorts while maintaining a systematic and manageable structure.
3Reliability
If a protrusion is added above terminal pins to prevent coil interference, then coil interference is inhibited, but automatic winding equipment cannot be used and production costs increase
Solution Approach 1:
Instead of adding a protrusion that would obstruct automated winding, the patent uses a multi-layer terminal pin arrangement that guides coil extension portions through different vertical layers. This dimensional separation prevents interference without requiring manual intervention, maintaining compatibility with automatic winding equipment.
4Reliability
If coil extension portions are wound around a protrusion to prevent interference, then coil interference is prevented, but process lead time and production costs increase
Solution Approach 1:
The patent segments the terminal accommodation space into multiple layers, allowing coil extension portions to be routed through different layers without requiring complex winding around protrusions. This simplified multi-layer routing can be performed by automatic winding equipment, maintaining high production efficiency while preventing coil interference.
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 inhibits interference or shorts between coils, allows for automated winding, reduces production costs and time, and enhances quality uniformity while maintaining a slim component size.
Implementation Method 1
a coil unit including primary coils and secondary coils wound around the bobbin unit
Data Source
AI summary
Disclosed is a magnetic component. The magnetic component of the disclosure includes a core unit including an upper core and a lower core, a bobbin unit having at least a portion disposed inside the core unit, and a coil unit including primary coils and secondary coils wound around the bobbin unit in a second direction, which is perpendicular to a first direction oriented from the upper core toward the lower core. The bobbin unit includes a first terminal accommodation portion and a second terminal accommodation portion. The first terminal accommodation portion accommodates first terminal pins, connected to at least some of the secondary coils in the second direction and having end portions bent in the first direction. The second terminal accommodation portion accommodates second terminal pins, connected to the remaining ones of the secondary coils in the second direction and having end portions bent in the first direction.