Inductance Element With Bent Resin Cover for Core Protection
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Solution Overview
Problem
Existing noise suppression elements for switching power supplies, particularly those using Co-based amorphous alloys, face challenges with magnetic characteristic degradation due to resin contraction and high production costs associated with separate metal molds for lidded containers, making them inefficient for small elements and mass production.
Innovation Solution
The development of an inductance element featuring a bottomed insulating resin case with a toroidal core and a cover portion formed by bending extending sections of the resin case, eliminating the need for separate lids and metal molds, and using a heated metal head to shape the cover portion, thereby reducing stress on the core and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a toroidal core using amorphous alloy ribbon is covered entirely with an insulating resin, then the core is protected from external factors, but the magnetic characteristics are degraded by stress from resin contraction
Solution Approach 1:
The insulating resin case is divided into a bottomed case portion and a separate cover portion. The cover portion is detached from the bottomed case, allowing the toroidal core to be housed in the bottomed case without being covered by resin that would contract and stress the core. The cover portion is subsequently attached to close the opening, providing protection without causing magnetic characteristic degradation.
Solution Approach 2:
The cover portion is extracted as a separate component from the bottomed insulating resin case. This separation allows the cover to be attached after the core is housed, avoiding the problem of resin contraction stress on the core while still providing the necessary protection when the cover is in place.
2Manufacturing precision
If a lidded container is used to house the core, then the magnetic characteristics are protected from degradation, but the production cost increases due to separate metal molds for lid and container body
Solution Approach 1:
The cover portion and the bottomed insulating resin case are merged into a single integrated component molded from one piece of insulating resin. This eliminates the need for separate metal molds for the lid and container body, reducing production cost while still providing the protective enclosure that prevents magnetic characteristic degradation.
Solution Approach 2:
The single insulating resin material serves multiple functions: it provides the bottomed case structure, the cover portion, and the protective enclosure for the toroidal core. This multi-functionality eliminates the need for separate components and molds, reducing manufacturing complexity and cost.
3Shape
If separate metal molds are prepared for lid and container body, then the structure can be properly formed, but the burden of production cost becomes large
Solution Approach 1:
The lid (cover portion) and container body (bottomed case portion) are merged into a single insulating resin component. This allows both parts to be formed in one molding process using a single mold, eliminating the need for separate metal molds and reducing production cost while maintaining the necessary structural form.
4Shape
If the lid and container body are assembled separately, then the structure can be formed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The cover portion and bottomed case portion are merged into a single insulating resin component that is molded as one piece. This eliminates the assembly step of joining separate lid and container body components, simplifying the manufacturing process and improving mass production efficiency.
Solution Approach 2:
The insulating resin case is molded with the cover portion and bottomed case portion as a single integrated structure before the toroidal core is housed. This preliminary formation of the complete case structure eliminates subsequent assembly steps, improving manufacturing efficiency.
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 solution enhances the magnetic characteristics of the inductance element, reduces production costs, and improves mass productivity by eliminating the need for separate lids and complex assembly processes, while maintaining effective noise reduction for small elements.
Implementation Method 1
a bent section which is formed by bending an extending section of the cylindrical outer wall section exceeding a height of the toroidal core toward the cylindrical inner wall section
Implementation Method 2
formed by bending an extending section... by bending... heated metal head
Data Source
AI summary
In one embodiment, an inductance element includes a toroidal core and a bottomed insulating resin case. The bottomed insulating resin case includes a cylindrical outer wall section, a cylindrical inner wall section, a bottom section, an open section and a hollow section. The cylindrical outer wall section has an extending section exceeding the height of the toroidal core. The open section of the insulating resin case is covered with a cover portion having a bent section formed by bending an extending section of the cylindrical outer wall section.