Grooved Magnetic Core Molding for High-Power Inductor Gap Filling
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Solution Overview
Problem
The challenge in one-piece injection molding of high-power inductors is the poor fluidity of high-temperature engineering plastics, which leads to incomplete filling of narrow gaps between the magnetic core and the coil, requiring increased injection pressure that causes mold wear and fragmentation of the magnetic core.
Innovation Solution
The design incorporates an annular magnetic core with grooved winding portions and an injection molding body that forms channels between the coil and the grooves, allowing for lower injection pressure and complete filling of the gap, while maintaining inductance characteristics and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If higher injection pressure is used to enhance the fluidity of high-temperature melts, then the filling of the gap between the magnetic core and the coil is improved, but mold wear increases and the magnetic core may fragment
Solution Approach 1:
The patent changes the physical parameters of the injection molding process by optimizing injection temperature and pressure within specific ranges, and modifies the geometric parameters of the magnetic core by adding grooves to the winding portions. These parameter changes improve melt fluidity and gap filling without requiring excessive injection pressure, thereby avoiding mold wear and magnetic core fragmentation
Solution Approach 2:
The patent segments the magnetic core structure by adding grooves to the winding portions. These grooves divide the solid magnetic core into regions that facilitate melt flow, creating channels that guide the high-temperature melt through the narrow gap between the magnetic core and coil, improving filling quality without increasing injection pressure
2Quantity of substance
If the gap between the magnetic core and the coil is minimized to reduce copper consumption, then the energy storage density is improved, but the fluidity of high-temperature melts deteriorates making it difficult to fill the gap
Solution Approach 1:
The patent segments the magnetic core winding portions with grooves that create internal channels. These grooves act as flow paths for the high-temperature melt, enabling the melt to reach and fill the narrow gap between the magnetic core and coil even when the gap is minimized for reduced copper consumption
Solution Approach 2:
The grooves on the magnetic core winding portions serve as an intermediary structure that mediates between the injection molding system and the narrow gap region. The grooves capture and guide the melt flow, acting as a bridge that enables filling of the minimized gap without compromising melt fluidity
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 enhances the injection performance, reduces material costs, and improves the mechanical and thermal properties of high-power inductors by minimizing the spatial distance between the coil and magnetic core, ensuring effective electrical insulation and heat conduction.
Implementation Method 1
the injection molding body may be filled in the injection molding channels and may constitute an integrally molded body together with the magnetic core and the coil
Implementation Method 2
using engineering plastics such as PPS having good heat resistance, insulation, thermal conductivity
Data Source
AI summary
An injection molded inductive apparatus, a powder magnetic core, and an injection molding method. The inductive apparatus comprises a magnetic core, a coil, and an injection molding body; the magnetic core is of an annular structure and is provided with two winding portions; one or more grooves are formed on the winding portions; the coil is wound on each winding portion, and an injection molding channel is formed between the inner side surface of the coil and the groove on the winding portion; and the injection molding body is filled along the injection molding channel, and constitutes an integrally molded body together with the magnetic core and the coil. According to the apparatus, one or more grooves are designed on the winding portions of the magnetic core, and the compact filling effect of the injection molding body in a gap between the coil and the magnetic core is achieved.