Inductance Element with Adhesive-Fixed Magnetic Core
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Solution Overview
Problem
Existing noise suppression elements for switching power supplies, such as those using Co-based amorphous magnetic materials, face challenges with resin contraction causing stress and degradation of magnetic characteristics, and require complex manufacturing processes that increase production costs and reduce mass productivity.
Innovation Solution
An inductance element comprising a doughnut-shaped magnetic core housed in a bottomed container with a conductive lead portion and an adhesive portion that fixes the core, container, and lead portion without a lid, allowing for improved mass production and reduced production costs, using a composition like CoaFebMcSidBe amorphous alloy and a manufacturing method involving liquid quenching and adhesive curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lidded container is used to house the core, then the magnetic characteristics are protected from degradation, but the device complexity and production cost increase due to separate lid and container body
Solution Approach 1:
The patent removes the lid component entirely from the container structure, converting it into an open-ended container. This extraction eliminates the complexity of assembling separate lid and container body parts while still providing the necessary protective function through the adhesive portion.
Solution Approach 2:
The patent merges the protective function previously distributed between lid and container body into a single integrated open-ended container structure with an adhesive portion. This consolidation reduces the number of parts and assembly steps while maintaining the essential protective function.
2Reliability
If a lidded container is used, then the magnetic characteristics are maintained, but the productivity decreases due to additional assembly steps for lid attachment
Solution Approach 1:
The patent extracts the lid component from the structure, eliminating the assembly step of attaching a separate lid. This reduces the number of manufacturing steps and improves mass production efficiency while still maintaining magnetic characteristics through the adhesive portion.
Solution Approach 2:
The patent segments the protective function into the adhesive portion applied to the open section, eliminating the need for a separate lid component. This reduces assembly complexity and improves productivity by removing the lid attachment step from the manufacturing process.
3Ease of manufacture
If separate metal molds are prepared for lid and container body, then the components can be produced, but the preparation percentage in production cost becomes large
Solution Approach 1:
The patent removes the lid component from the structure, eliminating the need for a separate metal mold for the lid. This reduces the number of metal molds required from two to one, significantly reducing mold preparation costs while still enabling component production.
Solution Approach 2:
The patent merges the lid and container body functions into a single open-ended container structure, reducing the number of metal molds needed from two to one. This consolidation directly reduces mold preparation costs and simplifies the manufacturing setup.
4Strength
If welding or fixing steps are added to attach the lid, then the container structure is completed, but the manufacturing process complexity increases
Solution Approach 1:
The patent extracts the lid component from the structure, eliminating the welding or fixing steps that would be required to attach it. This simplifies the manufacturing process by removing complex joining operations while still providing structural integrity through the adhesive portion.
Solution Approach 2:
The patent replaces the mechanical joining methods (welding or fixing) with a chemical bonding method using adhesive. This substitution eliminates the need for complex welding equipment and skilled operators, simplifying the manufacturing process while maintaining structural strength.
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 solution effectively suppresses magnetic characteristic degradation, simplifies production, and enhances mass productivity while maintaining excellent noise reduction capabilities, suitable for use in switching power supplies.
Implementation Method 1
an adhesive portion, disposed to cover the open section of the bottomed container, integrally fixing the doughnut-shaped magnetic core, the bottomed container and the conductive lead portion
Implementation Method 2
a Co-based amorphous material has excellent magnetic characteristics
Implementation Method 3
the noise reducing effect is better than the ferrite beads
Data Source
AI summary
An inductance element (1) includes a doughnut-shaped magnetic core (2) having a wound body or a stacked body of a magnetic ribbon, a bottomed container (3) in which the doughnut-shaped magnetic core (2) is housed, and a conductive lead portion (5) inserted into a hollow section of the doughnut-shaped magnetic core (2) housed in the bottomed container (3). An open section of the bottomed container (3) is covered with an adhesive portion (4) which integrally fixes the doughnut-shaped magnetic core (2), the bottomed container (3) and the conductive lead portion (5). The adhesive portion (4) is entered into a gap between the doughnut-shaped magnetic core (2) and the bottomed container (3) and a gap between the bottomed container (3) and the conductive lead portion (5) in a range of 5 to 50% in average to a thickness of the doughnut-shaped magnetic core (2).