Integrally Formed Inductor Pressing for Accurate Coil Positioning
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Solution Overview
Problem
Conventional integrally formed inductor manufacturing methods are complex, inefficient, and result in low material utilization and high costs due to the need for welding lead frames and embedding coils in soft magnetic metal powder, which can lead to skewed coil positions and reduced product performance.
Innovation Solution
A method involving arranging a coil into a mold, winding it into a predetermined shape, bending the lead wire onto the mold, and adding soft magnetic metal powder for pressing, eliminating the need for welding and ensuring proper coil positioning through pre-pressing and hot pressing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conventional manufacturing method uses welding to attach lead frame to coil and embedding in soft magnetic metal powder, then the inductor can be formed, but the production process becomes complex and efficiency is reduced
Solution Approach 1:
The patent merges the lead frame and coil into a single integrally formed component through die-casting, eliminating the need for separate welding and embedding operations. The lead frame structure is formed simultaneously with the soft magnetic metal powder core in one integrated manufacturing process, significantly simplifying the production process and improving efficiency.
Solution Approach 2:
The patent performs preliminary forming of the lead frame structure through die-casting before final assembly. The lead frame is pre-formed with appropriate dimensions and shapes during the initial casting process, eliminating the need for subsequent cutting and bending operations that were required in conventional methods.
2Quantity of substance
If the lead frame is embedded in soft magnetic metal powder, then the inductor structure is formed, but the pressed density of the soft magnetic metal powder is low and material characteristics cannot be fully exerted
Solution Approach 1:
The patent combines the lead frame and soft magnetic metal powder into a single integrated die-casting process, allowing the soft magnetic metal powder to be densely packed around the lead frame structure. This merging eliminates the embedding step that previously reduced powder density, enabling full utilization of the material characteristics.
Solution Approach 2:
The patent changes the manufacturing parameters by using die-casting instead of conventional embedding, which allows for higher density packing of the soft magnetic metal powder. The controlled casting process enables optimization of powder density and distribution, fully exerting the material characteristics.
3Loss of substance
If the lead frame is cut and bent to form electrodes, then the inductor structure is completed, but material is wasted and production cost increases
Solution Approach 1:
The patent performs preliminary forming of the lead frame electrodes during the die-casting process itself. The lead frame is cast with the final electrode shapes and dimensions already formed, eliminating the need for subsequent cutting and bending operations that cause material waste and increase costs.
Solution Approach 2:
The patent merges the electrode forming operation into the main die-casting process. The electrodes are formed as an integral part of the lead frame structure during casting, eliminating separate material removal operations and reducing both material waste and manufacturing costs.
4Manufacturing precision
If the coil is placed in the mold during production, then the inductor can be manufactured, but it cannot be ensured whether the coil satisfies the position requirement, causing skewed state and reduced product performance
Solution Approach 1:
The patent merges the coil positioning function into the die-casting mold design. The mold includes built-in positioning features and guides that automatically ensure the coil is correctly positioned during the casting process, eliminating the need for separate positioning checks and ensuring consistent accuracy.
Solution Approach 2:
The patent performs preliminary positioning of the coil within the mold before the actual casting process. The mold design includes pre-positioning mechanisms that ensure the coil is correctly located before the soft magnetic metal powder is cast, preventing skewed positions and ensuring product performance.
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 simplifies the coil structure, increases production efficiency, reduces costs, enhances material utilization, and ensures accurate coil positioning within the core, thereby improving the product characteristics of the integrally formed inductor.
Implementation Method 1
adding a soft magnetic metal powder into the mold and pressing the soft magnetic metal powder to obtain the integrally formed inductor
Implementation Method 2
adding the soft magnetic metal powder into the mold and performing hot pressing to obtain the integrally formed inductor
Data Source
AI summary
The present disclosure relates to an integrally formed inductor and a manufacturing method therefor. The method comprises: placing a coil into a mold, wherein the coil is wound in a predetermined shape; bending a lead of the coil onto the mold; and adding soft magnetic metal powder to the mold for pressing, so as to obtain an integrally formed inductor.