Heat Generator Top Plate Positioning for Accurate Component Mounting
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Solution Overview
Problem
Positioning errors between the case and the heat generator in electronic components, such as toroidal coils, can lead to misalignment during mounting, making it difficult to incorporate these components into electronic devices.
Innovation Solution
Incorporating a top plate with positioning holes or protrusions outside the case to fix the position of the heat generator relative to the electronic device, independent of the case's position, ensuring accurate alignment and easy integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the case and heat generator are combined in production, then manufacturing efficiency is improved, but positioning error between case and heat generator occurs
Solution Approach 1:
The heat generator is divided into two parts: the heat-generating element inside the case and the top plate outside the case. The top plate includes positioning holes that serve as a positioner, separating the heat generation function from the positioning function. This segmentation allows the heat generator to be combined with the case in production while maintaining positioning accuracy through the top plate's positioning holes.
Solution Approach 2:
The top plate acts as an intermediary between the heat-generating element and the electronic device. It provides positioning holes that enable accurate positioning relative to the electronic device, while the heat-generating element remains inside the case. This intermediary structure resolves the contradiction by providing a reference for positioning that is independent of the case-heat generator assembly accuracy.
2Stability of the object's composition
If the case is fixed at a given location, then mounting stability is improved, but terminal misalignment occurs due to positioning error
Solution Approach 1:
The heat generator's top plate is segmented from the case, with the top plate extending outside the case to provide positioning holes. This segmentation allows the case to be fixed stably at a given location while the top plate's positioning holes ensure terminal alignment with the electronic device, resolving the contradiction between mounting stability and terminal alignment.
Solution Approach 2:
The top plate extends in a different dimension (outside the case) to provide positioning functionality. This dimensional extension allows the positioning holes to be accessible for alignment with the electronic device while the case remains fixed, separating the stabilization function (case) from the alignment function (top plate).
3Manufacturing precision
If the top plate is located outside the case, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The top plate merges multiple functions: it serves as part of the heat generator structure, provides positioning holes for accurate positioning, and extends outside the case to enable alignment. By combining these functions into a single component, the invention achieves positioning accuracy without proportionally increasing device complexity.
Solution Approach 2:
The top plate is a multi-functional component that provides both structural support for the heat generator and positioning reference through its positioning holes. This universality reduces the need for separate positioning components, thereby limiting the increase in device complexity while achieving improved positioning accuracy.
Data Source
AI summary
An electronic component 2 includes a heat generator 4 and a case 6. The heat generator 4 includes a heat-generating element 24 located inside the case 6 and a top plate 14 located at least in part outside the case 6. The top plate 14 includes a positioner for fixing a position of the heat generator 4 relative to an electronic device. Preferably, the case 6 includes an opening at its upper surface, the top plate 14 includes a lid 18 covering the opening and a protrusion 20 extending from the lid 18 and projecting from the case 6 in plan view, and the positioner is a positioning hole 22 located in the protrusion 20.