Flexible Electrode Inductor Assembly for Vibration-Resistant Connections
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Solution Overview
Problem
Conventional inductors lack reliable connections to external circuits, leading to potential malfunctions and reduced performance due to gaps and vulnerabilities in the joining parts, which can be exacerbated by vibrations in use environments.
Innovation Solution
An inductor design featuring a magnetic core with a three-dimensional shape, a coil element with embedded and exposed portions, and a flexible electrode member that overlaps and is welded to the coil element, ensuring stable adhesion and integration through an adhesive layer, allowing for reliable electrical connections and enhanced resistance to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional inductor joining methods are used, then manufacturing is simpler, but connection reliability deteriorates due to gaps and vulnerabilities in joining parts
Solution Approach 1:
The electrode member is integrated with both the magnetic core (via adhesion layer) and the coil element (via welding), merging three separate components into a unified structure. This eliminates gaps between components and ensures reliable electrical connection while maintaining structural integrity under vibration.
Solution Approach 2:
The electrode member is positioned to overlap with the coil element's end portion before welding. This preliminary positioning ensures proper alignment and contact between the electrode member and coil element, enabling reliable welding and preventing connection failures during subsequent manufacturing or usage.
2Object-affected harmful factors
If the electrode member is made flexible, then resistance to vibrations improves, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The electrode member's flexibility is achieved by controlling its material properties and geometric parameters (such as thickness and width). This flexibility allows the electrode member to accommodate vibrations and thermal expansions while the overlapping configuration with the coil element ensures consistent electrical connection despite dimensional variations.
3Reliability
If the electrode member overlaps the coil element, then connection reliability improves through dual bonding, but device complexity increases
Solution Approach 1:
The connection between the electrode member and coil element is divided into two distinct bonding mechanisms: adhesion between the electrode member and magnetic core, and welding between the electrode member and coil element. This segmentation allows each bonding method to be optimized independently while working together to ensure overall connection reliability.
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 provides higher connection reliability by ensuring stable electrical connections and reducing the risk of damage from vibrations, maintaining performance and preventing malfunctions.
Implementation Method 1
the electrode member and the magnetic core are adhered to each other via an adhesion layer including resin that is adhesive
Implementation Method 2
the electrode member and the end portion are welded together at least in a part of a region in which the side face portion and the end portion overlap each other
Data Source
AI summary
An inductor includes: a magnetic core including a magnetic material and having a three-dimensional shape and a side face; a coil element including a metallic material, an embedded portion embedded in the magnetic core, and an end portion exposed from the magnetic core and extending along the side face; and an electrode member including a metallic material, having flexibility, and disposed opposite to the magnetic core across the end portion. The electrode member includes a side face portion disposed along the side face and at least partially overlapping the end portion as viewed in a thickness direction of the side face portion. The electrode member and the magnetic core are adhered via an adhesion layer including resin that is adhesive. The electrode member and the end portion are welded together at least in a part of a region in which the side face portion and the end portion overlap.