Transformer Coil Pin Layout for Compact Insulated Lead Routing
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Solution Overview
Problem
In coil transformers, the distance between pin terminals can lead to reduced wire diameter for lead wires, causing short circuits. Increasing the size of the pin terminal embedding portion to accommodate more terminals results in a larger bobbin size.
Innovation Solution
A coil device with a bobbin that includes a winding core, a coil wound around it, and a pin terminal block with pin terminal groove portions and pin fixing portions. This configuration allows for a reduced overall size while maintaining an adequate insulation distance between lead wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the distance between pin terminals is reduced to accommodate more terminals, then the number of pin terminals increases, but the insulation distance between lead wires decreases causing short circuit risk
Solution Approach 1:
The patent transitions from a planar arrangement of pin terminals to a three-dimensional structure by forming pin terminal groove portions that extend in the axial direction of the winding core portion. This vertical dimensionality allows pin terminals to be arranged both radially and axially, increasing the number of terminals without reducing the insulation distance between lead wires on the circuit board.
Solution Approach 2:
The pin terminals are nested within groove portions formed in the pin terminal block, with each groove containing a pin terminal fixed at its bottom surface. This nested structure efficiently packs multiple pin terminals into a compact space while maintaining proper spacing and insulation distances.
2Quantity of substance
If additional pin terminals are added to secure necessary connections, then the number of pin terminals increases, but the size of the pin terminal embedding portion increases
Solution Approach 1:
By utilizing the axial direction of the winding core portion to form groove portions, the patent accommodates more pin terminals vertically rather than expanding the radial area. This allows increased terminal count without proportionally increasing the overall size of the pin terminal embedding portion.
Solution Approach 2:
The pin terminal block is integrated with the flange portion of the bobbin, combining multiple functions into a single structure. This merging reduces the need for separate embedding portions and minimizes the overall space required for terminal accommodation.
3Quantity of substance
If the size of the pin terminal embedding portion is increased to accommodate more terminals, then the number of pin terminals increases, but the size of the bobbin increases
Solution Approach 1:
The patent employs the axial dimension of the bobbin to arrange pin terminals vertically through groove portions, rather than expanding the radial or lateral dimensions. This allows increased terminal capacity without increasing the overall bobbin volume.
Solution Approach 2:
The groove portions are strategically formed only in specific regions of the pin terminal block where needed for terminal accommodation, rather than uniformly expanding the entire structure. This localized approach minimizes the impact on overall bobbin size while providing necessary terminal capacity.
Data Source
AI summary
A coil device of the present application includes a bobbin including a winding core portion, a coil wound around the winding core portion, a flange portion provided integrally with the winding core portion, a pin terminal block provided integrally with the flange portion, a plurality of pin terminals (P) provided at predetermined intervals at the pin terminal block and connected to lead wires of the coil, and a circuit board connected to the plurality of pin terminals (P). The pin terminal block includes a plurality of pin terminal groove portions formed in a groove shape along an axial direction of the winding core portion, and a pin fixing portion formed in an interior space of the pin terminal groove and integrally fixed to one end of the pin terminal (P).