Inductance Element with Bottomed Container and Adhesive
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Solution Overview
Problem
Existing noise suppression elements for switching power supplies, such as those using Co-based amorphous materials, face issues with magnetic characteristic degradation due to resin contraction and require complex manufacturing processes, including separate metal molds and assembly steps, which increase production costs and reduce mass productivity.
Innovation Solution
An inductance element with a doughnut-shaped magnetic core housed in a bottomed container, where the core is integrally fixed using an adhesive portion with an extended portion, eliminating the need for a lid and simplifying the manufacturing process by using a single metal mold for the container and avoiding assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a Co-based amorphous magnetic ribbon is covered entirely with resin, then the noise reducing effect is improved, but the magnetic characteristics are degraded due to resin penetration and contraction stress
Solution Approach 1:
The resin coating is segmented into two distinct regions: a first resin layer that does not contact the magnetic ribbon, and a second resin layer that contacts and covers the magnetic ribbon. This segmentation prevents the harmful effects of complete resin coverage while maintaining noise suppression benefits.
Solution Approach 2:
Different regions of the magnetic ribbon are treated differently: the circumferential surface is covered with resin for noise suppression, while the radial surfaces remain exposed or minimally covered to prevent resin penetration and contraction stress that would degrade magnetic characteristics.
2Reliability
If a lidded container is used to house the core, then the magnetic characteristics are protected from degradation, but the device complexity and manufacturing cost increase due to separate metal molds and assembly steps
Solution Approach 1:
The lid portion is extracted and eliminated from the container structure. The container is redesigned as an open-topped cylindrical structure that houses the magnetic core without requiring a separate lid, thereby simplifying the overall structure while maintaining protective functions through the resin coating system.
Solution Approach 2:
The protective function previously separated into lid and container body is merged into the container structure itself, with the resin coating providing both noise suppression and protection against magnetic characteristic degradation in a unified system.
3Reliability
If a lidded container with separate lid and container body is used, then the magnetic characteristics are protected, but the productivity is reduced due to additional assembly steps
Solution Approach 1:
The lid component and its associated assembly step are extracted and eliminated. The container is designed as a single-piece open-topped structure that can be manufactured in one molding process, eliminating the need for separate lid assembly operations and improving mass production efficiency.
4Strength
If the resin is allowed to contract when dried, then the resin provides structural support, but the stress applied to the toroidal core degrades the magnetic characteristics
Solution Approach 1:
The resin coating is segmented into regions with different functions: the first resin layer provides structural support without contacting the magnetic ribbon, while the second resin layer contacts the magnetic ribbon but is positioned to avoid causing contraction stress during drying.
Solution Approach 2:
The resin is configured in advance to dry and contract away from the magnetic ribbon, creating a protective configuration before the magnetic core is subjected to operational stresses. The preliminary arrangement of resin layers prevents harmful stress application.
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 effectively prevents magnetic characteristic degradation, reduces production costs, and enhances mass productivity by simplifying the manufacturing process and eliminating the need for separate metal molds and assembly steps, while maintaining strong bonding and insulating properties.
Implementation Method 1
an adhesive portion, disposed on the side of the open section of the bottomed container, integrally fixing the doughnut-shaped magnetic core and the bottomed container
Data Source
AI summary
An inductance element (1) includes a doughnut-shaped magnetic core (2) and a bottomed container (3) for housing the doughnut-shaped magnetic core (2). The bottomed container (3) has a cylindrical outer wall portion, a cylindrical inner wall portion, a bottom portion, an open section and a hollow portion. The open section of the bottomed container (3) is covered with an adhesive portion (4) for integrally fixing the doughnut-shaped magnetic core (2) and the bottomed container (3). The adhesive portion (4) has an extended portion (4a) extended in the cylindrical inner wall portion. The ratio (B/A) of a length (B) of the extended portion (4a) to a height (A) of the cylindrical inner wall portion is in a range of 0.1 to 0.5.