Flat-Wire Inductor Notch Structure for Insulation Reliability
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Solution Overview
Problem
Inductors with coil elements formed using flat wires face reliability issues due to reduced insulation properties between wire portions caused by bending, leading to potential damage of insulation coatings and increased proximity of wire sections.
Innovation Solution
The inductor design includes a magnetic core formed by pressure molding a mixture of magnetic material powder and a binder, with a coil element featuring a flat wire having an insulation coating and bent portions with notch structures to manage wire expansion, ensuring equal end portion heights and maintaining insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flat wire is bent to form coil element, then coil element can be formed with compact shape, but insulation properties between wire portions are reduced
Solution Approach 1:
The patent applies preliminary action by forming the notch structure on the flat wire before bending it into the coil element. This pre-formed notch creates controlled spacing between adjacent wire portions, preventing insulation damage during the bending process. The notch is created at a specific position on the pull-out portion of the flat wire, which will later become the bent portion in the coil element, thereby proactively solving the insulation problem before it occurs.
Solution Approach 2:
The patent applies local quality by creating a notch structure at a specific location on the flat wire rather than uniformly modifying the entire wire. The notch is positioned on the pull-out portion that will be bent, creating local spacing only where needed to prevent insulation damage between adjacent turns. This localized modification maintains the overall compact coil shape while protecting insulation only where the bending process creates proximity issues.
2Volume of moving object
If flat wire is bent closely, then coil element size is reduced, but wire portions are positioned close to each other reducing insulation
Solution Approach 1:
The patent applies local quality by creating a notch structure at a specific location on the flat wire rather than uniformly modifying the entire wire. The notch is positioned on the pull-out portion that will be bent, creating local spacing only where needed to prevent insulation damage between adjacent turns. This localized modification maintains the overall compact coil shape while protecting insulation only where the bending process creates proximity issues.
Solution Approach 2:
The patent applies preliminary action by forming the notch structure on the flat wire before bending it into the coil element. This pre-formed notch creates controlled spacing between adjacent wire portions, preventing insulation damage during the bending process. The notch is created at a specific position on the pull-out portion of the flat wire, which will later become the bent portion in the coil element, thereby proactively solving the insulation problem before it occurs.
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 design enhances the reliability of the inductor by minimizing insulation reduction and maintaining insulation properties, thus improving the overall performance and durability.
Implementation Method 1
a magnetic core (10) including a bottom surface (11) and a side surface (13c) connected to the bottom surface (11), the magnetic core (10) being provided by pressure molding a mixture of a magnetic material powder and a binder
Data Source
AI summary
An inductor (100) includes: a magnetic core (10) including a bottom surface (11) (first surface); and a coil element (20) including a flat wire. The coil element (20) includes a wound coil (21) and a first pull-out portion (22) connected to the coil (21) and one (first end portion (25)) of two end portions of the flat wire. The first pull-out portion (22) includes two or more bent portions (31) formed by bending the flat wire in an extension direction of the flat wire, each of the two or more bent portions (31) having a valley (32) on a surface of the flat wire. One of the two or more bent portions (31) that is located closest to the coil (21) has, in the valley (32), a notch structure (33) that is dented toward inside of the flat wire. The notch structure (33) has a deeper dent depth on one end side of the valley (32) closer to a winding axis (B) of the coil (21) when compared to a dent depth on an other end side of the valley (32) far from the winding axis (B) of the coil (21).