Coil Component Segmented Core and Cover Assembly
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Solution Overview
Problem
Existing wire-wound inductor manufacturing methods face challenges in achieving desired characteristics such as inductance and DC bias characteristics due to issues like insulating layer stripping and coil dislocation during pressing and molding.
Innovation Solution
A novel structure for a coil component is proposed, where the core, coil, and cover are separately manufactured and assembled, allowing for high-pressure molding to improve magnetic material fill factor and prevent coil dislocation, with the coil and cover formed using magnetic powder particles and thermosetting resins, and the lead embedded in the flange portion to enhance mechanical strength and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire-wound inductors are manufactured by positioning a wound coil in a mold, filling magnetic powder particles, and pressing and molding, then the inductor structure is formed, but insulating layer stripping and coil dislocation occur during pressing and molding
Solution Approach 1:
The patent divides the inductor into separate components: the coil is wound and insulated separately, then positioned on a magnetic powder core, and finally covered with a protective cover. This segmentation allows the coil to be prepared with intact insulating layers before assembly, avoiding the stripping problem that occurs when the coil is embedded in a single-step molding process.
Solution Approach 2:
The coil is wound and its insulating layers are applied in advance before the assembly process. The coil is then positioned on the magnetic powder core with the insulating layers already in place, preventing the insulating layer stripping that occurs during simultaneous molding. This preliminary preparation ensures the coil maintains its structural integrity throughout assembly.
2Manufacturing precision
If high-pressure molding is applied to improve magnetic material fill factor, then the magnetic material density increases, but coil dislocation occurs
Solution Approach 1:
The patent separates the coil positioning step from the magnetic powder filling and molding step. The coil is first positioned on the magnetic powder core in a low-pressure state, then the cover is added, and finally high-pressure molding is applied to fill the magnetic powder. This segmentation allows high fill factor to be achieved without disrupting the pre-positioned coil.
Solution Approach 2:
The coil is positioned in advance on the magnetic powder core before the high-pressure molding process. This preliminary positioning ensures the coil is securely placed and cannot be dislocated during the subsequent high-pressure filling process, as the coil structure is already established and protected by the cover.
3Ease of manufacture
If the coil is wound and positioned in a mold before filling magnetic powder, then the inductor assembly is complete, but the manufacturing process is complex and difficult to mass produce
Solution Approach 1:
The patent divides the manufacturing process into independent, modular steps: coil winding, core preparation, assembly, and molding. Each step can be performed separately and optimized independently, simplifying the overall process and enabling parallel production lines for mass manufacturing.
Solution Approach 2:
The coil is wound and prepared in advance as a separate component, and the magnetic powder core is prepared separately. These pre-prepared components are then quickly assembled by placing the coil on the core and adding the cover, followed by a single molding step. This preliminary preparation of components significantly reduces assembly time and complexity, improving mass production efficiency.
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 approach enables the achievement of improved inductance, DC bias characteristics, and mechanical strength, facilitating mass production and reducing the risk of component separation.
Implementation Method 1
the coil and cover formed using magnetic powder particles and thermosetting resins
Data Source
AI summary
A coil component includes a core including a winding portion and a flange portion extending from a first end of the winding portion, a coil wound around the winding portion, a lead formed at the flange portion, and a cover coupled to the flange portion and covering at least a portion of the coil.