Conductive Member Module Positioning via Asymmetric Recesses
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Solution Overview
Problem
Conductive member modules face variations in the distance between conductive members due to thickness variations, leading to inconsistent parasitic inductance, as existing methods do not effectively manage the distance between these members during the production process.
Innovation Solution
The method involves accommodating conductive members in a molding die with outer and inner support members that form deeper outer recesses than inner recesses, ensuring the conductive members are securely positioned and preventing them from moving, allowing for consistent sealing and extraction while absorbing thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding methods are used without special positioning structures, then the production process is simple, but the distance between conductive members varies due to thickness variations
Solution Approach 1:
The molding die is designed with pre-formed recesses at specific positions where conductive members will be placed. These recesses are created beforehand in the die structure, allowing conductive members to be positioned at predetermined locations before the molding process begins, thereby compensating for thickness variations
Solution Approach 2:
The recesses in the molding die act as an intermediary structure between the conductive members and the final sealed product. These recesses provide a reference surface that ensures consistent positioning and spacing of conductive members, mediating the effect of thickness variations
2Manufacturing precision
If support members are used to position conductive members, then positioning precision improves, but the accommodation step becomes more complex
Solution Approach 1:
The positioning function and the sealing function are merged into a single integrated molding die structure. The recesses that position the conductive members are formed as integral parts of the die, eliminating the need for separate support members and simplifying the overall manufacturing process
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 reduces significant variations in the distance between conductive members, thereby stabilizing parasitic inductance and ensuring consistent performance, even with variations in conductive member thickness.
Implementation Method 1
a sealing step of injecting a fluid resin into the die to seal the pair of conductive members
Data Source
AI summary
A conductive member module has a pair of conductive members formed in a plate shape and facing each other, and a sealing part. The conductive member module is produced by performing an accommodation step, a sealing step, and an extraction step. In the accommodation step, the two individual conductive members are sandwiched in the facing orientation thereof by outer support members abutting outer surfaces of the conductive members, and inner support members abutting inner surfaces of the conductive members. Outer recesses are formed in the outer surfaces by the outer support members, and inner recesses are formed in the inner surfaces by the inner support members. The outer recesses are deeper in the Z direction than the inner recesses.