Batch-Fabricated Inductor Structure for Compact Electrode Formation
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Solution Overview
Problem
Conventional power inductors face issues with space inefficiency due to the use of lead frames and are prone to deformation and short circuits when heated, which affects their performance in smaller electronic components.
Innovation Solution
A method for forming multiple inductors in a single process where coils are fully encapsulated before pressure application, with the terminal part of the conductive wire exposed from the magnetic body to prevent deformation and increase electrode contact area, using a multi-layer magnetic structure with different particle sizes for enhanced encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead frames are used for forming electrodes, then electrode formation is simplified, but space consumption increases significantly
Solution Approach 1:
The patent extracts and eliminates the lead frame component from the inductor structure, replacing it with a magnetic body that directly serves as the electrode support. This removal of the unnecessary lead frame reduces space consumption while the magnetic body itself provides the electrode function, maintaining ease of manufacture.
Solution Approach 2:
The magnetic body is designed to serve multiple functions simultaneously: it provides magnetic shielding, structural support, and electrode formation. By making the magnetic body multi-functional, the patent eliminates the need for separate lead frames, thereby reducing space consumption while maintaining manufacturing simplicity.
2Manufacturing precision
If pressure is applied to fill magnetic powder, then magnetic body density increases, but coil deformation occurs causing short circuits
Solution Approach 1:
The patent applies preliminary action by pre-forming the magnetic body with appropriate density and structural support before coil placement. The magnetic body is prepared in advance with the right properties to prevent coil deformation during subsequent pressing operations, thus maintaining both density and coil integrity.
Solution Approach 2:
The patent implements beforehand cushioning by designing the magnetic body structure to provide protective support to the coil before pressure is applied. The magnetic body acts as a cushioning medium that distributes pressure evenly, preventing localized deformation that could cause short circuits while still achieving the desired density.
3Manufacturing precision
If coil is heated and pressed, then magnetic powder fills gaps, but particles penetrate insulating layer causing short circuits
Solution Approach 1:
The patent applies parameter changes by carefully controlling the heating and pressing parameters to achieve optimal magnetic powder distribution without excessive force or temperature that would cause particle penetration. By adjusting these parameters, the patent maintains both good powder distribution and insulating layer integrity.
4Manufacturing precision
If multiple inductors are produced separately, then each inductor quality is controlled, but production time and cost increase
Solution Approach 1:
The patent merges multiple inductor production processes into a single integrated manufacturing step. By combining the production of multiple inductors in one process, the patent achieves both high production efficiency and maintained quality control through unified process parameters and consistent magnetic body formation.
Solution Approach 2:
The patent makes the manufacturing process universal by creating a single process that can produce multiple inductors simultaneously with consistent quality. This multi-functional approach allows one process to serve multiple production needs, improving productivity while maintaining quality standards across all produced inductors.
Data Source
AI summary
A method to form a plurality of inductors in a single process by placing multiple coils on a first magnetic sheet, and then stacking magnetic layers on the first magnetic sheet to encapsulate the coils so as to from a large magnetic body, and then cutting the large magnetic body into multiple inductors, wherein a terminal part of the coil disposed on the bottom surface of the magnetic body of the inductor is extended away from the axis of the coil and is entirely located at a same side of the axis of the coil.