Hollow-Core Inductor Assembly Using U-Shaped Conductors
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Solution Overview
Problem
The traditional winding process for manufacturing inductors is time-consuming and costly, requiring significant manpower and leading to excessive production time and costs.
Innovation Solution
The use of a hollow magnetic core with a winding assembly comprising U-shaped conductors and conductive structures that are easily assembled by inserting them into a carrier board, forming a conductive path around the core to create an inductor device with high inductance and impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional winding process is used to manufacture inductors, then the inductors can be produced with proper inductance and impedance, but the production time and manufacturing cost increase significantly
Solution Approach 1:
The winding assembly is divided into multiple U-shaped conductors instead of a single continuous winding. Each U-shaped conductor can be independently positioned and connected, allowing for parallel assembly operations and eliminating the time-consuming sequential winding process while maintaining the necessary inductance and impedance characteristics
Solution Approach 2:
The traditional mechanical winding process is replaced with a structured assembly of U-shaped conductors that are positioned and connected through simpler mechanical means. The conductors are arranged in a predetermined pattern and electrically connected to form the winding assembly, substituting complex mechanical winding operations with easier assembly steps
2Ease of manufacture
If traditional winding process is used to manufacture inductors, then the inductors can be produced with proper inductance and impedance, but the manpower requirements and manufacturing cost increase
Solution Approach 1:
The winding assembly is segmented into multiple U-shaped conductors that can be independently handled and assembled. This segmentation allows for distributed assembly operations, reducing the concentration of manpower requirements and enabling easier automation or outsourcing of assembly tasks
Solution Approach 2:
The U-shaped conductors are pre-formed with their specific geometries and connection points before assembly. This preliminary preparation of components eliminates the need for complex on-site winding operations, significantly reducing the skilled manpower required during the final assembly process
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 method significantly reduces production time and costs by simplifying the assembly process, enabling the efficient manufacture of inductors with outstanding inductance and high impedance.
Implementation Method 1
When the current flowing through the inductor is changing, the electromotive force is generated to oppose the current change
Data Source
AI summary
An inductor device includes a hollow magnetic core and at least one winding assembly. The winding assembly includes a plurality of conductive structures and U-shaped conductors, and the conductive structures are below the hollow magnetic core. The conductive structures are arranged along a segment of the hollow magnetic core, and the U-shaped conductors are across the hollow magnetic core and arranged along the segment of the hollow magnetic core. Two ends of at least one of the U-shaped conductor are respectively in contact with two of the conductive structures such that the U-shaped conductors and the conductive structures are electrically connected to each other and collectively continuously surround the segment of the hollow magnetic core.