Inductance Element Resin Case With Self-Aligning Recesses
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Solution Overview
Problem
Current inductance element assembly processes face challenges in positioning contact surfaces and managing core gaps, leading to complex assembly procedures and the need for multiple molding dies, especially when using compressed magnetic cores or varying resin case shapes.
Innovation Solution
The inductance element resin case is designed as an assembly of divided members with complementary recesses and projections for precise fitting, allowing for simplified positioning and gap management, reducing the number of required molding dies and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If divided resin cases are assembled using conventional methods with metal bands or adhesives, then magnetic cores can be fixed, but assembly processing becomes complicated and automation is difficult
Solution Approach 1:
The invention merges the fixing function into the resin case structure itself by forming projections and recesses directly on the case members. This eliminates the need for separate fixing components like metal bands or adhesives, thereby simplifying assembly processing while maintaining reliable magnetic core fixation.
Solution Approach 2:
The resin case members are designed with self-aligning projections and recesses that automatically position and secure the magnetic cores during assembly. This self-service mechanism eliminates the need for complex external fixing devices or multi-step assembly procedures, enabling both reliable fixation and simplified processing.
2Adaptability or versatility
If multiple divided members with different shapes are used for resin cases, then various magnetic core configurations can be accommodated, but the number of molding dies increases
Solution Approach 1:
The invention designs the resin case members with universal features - projections and recesses that can be assembled in multiple configurations. The same basic case member shape can accommodate different magnetic core arrangements through various assembly combinations, eliminating the need for multiple specialized molding dies while maintaining versatility.
Solution Approach 2:
The projections and recesses are designed with asymmetric features that enable multiple valid assembly configurations from identical case members. This asymmetric design allows the same molded part to serve multiple purposes in different orientations and arrangements, reducing the number of required molding dies while accommodating various magnetic core configurations.
3Ease of operation
If contact surfaces of divided resin cases are assembled without precise positioning features, then assembly is simpler, but positioning accuracy of contact surfaces deteriorates
Solution Approach 1:
The projections and recesses serve as self-positioning features that automatically align contact surfaces during assembly. This self-service positioning mechanism maintains high positioning accuracy while keeping the assembly process simple, as the features guide the parts into correct alignment without requiring complex external positioning devices or procedures.
Data Source
AI summary
The present invention facilitates positioning of contact surfaces of a resin case, core gap management, and assembling processing. A resin case 1 can house at least one magnetic core selected from a U-shaped magnetic core, a UU-shaped magnetic core, a UR-shaped magnetic core, and an I-shaped magnetic core. The resin case 1 is used for an inductance element in which a coil is arranged around the magnetic core so as to house the magnetic core. The resin case is an assembly of a plurality of divided members with the same shape. A recess and a projection A1, A2 mutually fitted complementary to each other are formed on end surfaces of the divided members contacted with each other.