Ceramic Core Design for Increased Winding Area
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Solution Overview
Problem
Existing ceramic core manufacturing methods struggle to achieve increased winding area while maintaining miniaturization, leading to challenges in producing ceramic cores with sufficient strength and compactness for modern electronic devices.
Innovation Solution
A ceramic core design with an axial core part and flanges that have a specific dimension ratio, allowing for increased winding area while maintaining miniaturization, along with a manufacturing method using segmented punches for controlled compaction to minimize differences in compaction density between the axial core part and flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the ceramic core is miniaturized to meet demands of smaller electronic devices, then the size of the ceramic core is reduced, but the winding area available for coil formation is decreased
Solution Approach 1:
The invention transitions from a conventional integrated structure to a separated structure where the axial core part and flange are formed as distinct components. This dimensional separation allows the flange to extend radially outward, increasing the winding area available on the flange surface while keeping the axial core part compact for miniaturization. The winding can be formed on the flange's outer surface, effectively utilizing the radial dimension to increase winding area without increasing the overall footprint of the ceramic core.
2Strength
If the flange thickness is increased to provide sufficient strength, then the mechanical strength is improved, but the compaction density uniformity between the axial core part and flange deteriorates
Solution Approach 1:
The invention segments the ceramic core into two distinct parts: the axial core part and the flange. By forming these as separate green compacts and then joining them, the invention allows independent optimization of each part's thickness and compaction parameters. The flange can be made sufficiently thick for strength requirements, while the axial core part maintains appropriate dimensions for electrical performance, avoiding the compaction density uniformity issues that would arise from attempting to form a single thick integrated structure.
Solution Approach 2:
The invention performs preliminary formation of the axial core part and flange as separate green compacts before joining them. This preliminary action allows each component to be independently compacted to the appropriate density for its specific function, and then joined together. This approach prevents the compaction density uniformity problems that would occur if a single thick structure were compacted as one piece, while still achieving the required flange strength through controlled thickness.
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
The solution enables the production of ceramic cores with increased winding area, enhancing the inductance value of coil components and maintaining strength by minimizing compaction density differences, thus addressing the challenges of miniaturization and strength in ceramic core manufacturing.
Implementation Method 1
the ceramic powder filled in the fill cavity is pressed with a lower punch and upper punches to compact the ceramic powder into a green compact
Implementation Method 2
The green compact is then fired to produce a ceramic core
Data Source
AI summary
A ceramic core includes an axial core part extended in the longitudinal direction, and a pair of flanges located at both ends in the longitudinal direction of the axial core part and projecting around the periphery of the axial core part in the height and width directions. The ceramic core has a length dimension L in the longitudinal direction of about 0 mm<L≤1.1 mm. A ratio t/T of the thickness dimension t in the height direction of the axial core part to the height dimension T in the height dimension of the flanges, is about 0<t/T≤0.6. A ratio w/W of the width dimension w in the width direction of the axial core part to the width dimension W in the width direction of the flanges, is about 0<w/W≤0.6.