Coil Component Magnet Locking Structure for Vibration Stability
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Solution Overview
Problem
The existing coil components face a challenge with magnet positional dislocation, which leads to deterioration in DC superimposition characteristics during vibration.
Innovation Solution
A coil component design that includes a first core with leg portions, a second core joined to the first core, and a magnet positioned between the leg portions, where an uneven structure on the junction surface restricts the magnet's movement, preventing positional dislocation by forming restriction wall portions and protruding portions to secure the magnet in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet is disposed between the first core and the second core to enhance DC superimposition characteristics, then the DC superimposition characteristics are improved, but the magnet may positionally dislocate when the coil component vibrates
Solution Approach 1:
The junction surface between the magnet and the core is divided into multiple uneven portions (protrusions and recesses). These segmented features create multiple contact points that collectively restrict magnet movement in various directions, preventing positional dislocation while maintaining the magnetic circuit's integrity
Solution Approach 2:
The junction surface features asymmetric protrusions and recesses that are strategically positioned to restrict magnet movement. The asymmetric geometry creates directional constraints that prevent the magnet from shifting during vibration, while the overall symmetric arrangement of opposing restriction walls maintains balanced mechanical forces
2Stability of the object's composition
If an uneven structure is provided on the junction surface to restrict magnet movement, then positional dislocation is prevented, but the manufacturing complexity increases
Solution Approach 1:
The uneven structure is applied locally only at the junction surface between the magnet and the core, rather than throughout the entire component. This localized approach restricts magnet movement where needed while keeping the rest of the structure simple and easy to manufacture
Solution Approach 2:
The uneven structure is formed as an integral part of the core during the molding process, before assembly. This preliminary formation of restriction features eliminates the need for separate machining or assembly steps, reducing overall manufacturing complexity despite the increased local geometric complexity
3Stability of the object's composition
If restriction wall portions are formed to restrict magnet movement in multiple directions, then positional dislocation is effectively prevented, but the device complexity increases
Solution Approach 1:
Multiple restriction wall portions (first, second, third, and fourth restriction walls) are merged into a single integrated uneven structure on the junction surface. This unified structure performs multiple restriction functions simultaneously, preventing magnet movement in all directions without requiring separate independent components
Solution Approach 2:
The uneven structure serves multiple functions: it restricts magnet movement in multiple directions, provides mechanical anchoring, and maintains the magnetic circuit gap. This multi-functionality reduces the need for additional separate components, offsetting the complexity of the geometric features
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
Enhances DC superimposition characteristics by restricting magnet movement, thereby preventing positional dislocation and improving manufacturing efficiency through facilitated positioning and mounting.
Implementation Method 1
Movement of the magnet in a first direction intersecting an opposite direction in which the first core and the second core face each other is at least restricted by an uneven structure provided on a junction surface between the magnet and at least one of the first core and the second core
Data Source
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AI summary
A coil component includes a first core having a leg portion, a second core joined to the first core with the leg portion therebetween, and a magnet disposed between the leg portion and the second core. Movement of the magnet in a first direction intersecting a direction in which the first core and the second core face each other is at least restricted by an uneven structure provided on a junction surface between the magnet and at least one of the first core and the second core.