Induction Component Carrier Element Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing induction components face challenges in achieving reliable and automatic assembly due to loose wire ends that do not always lie in one plane, necessitating complex bending or additional connection methods.
Innovation Solution
An induction component design featuring a housing with a carrier element that includes connection contacts and connection configurations for the winding ends, allowing for reliable connection independent of the wire end shape, with options for manufacturing ease and secure attachment to a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If loose wire ends are used for connection, then manufacturing is simpler, but the wire ends do not lie in one plane making SMD assembly difficult
Solution Approach 1:
The connection system is divided into separate functional elements: the coil winding (which remains simple and loose) and the connection contacts (which provide the planar interface). The carrier element separates these functions, allowing the coil to be wound freely while the connection contacts are independently positioned on the carrier to ensure planarity for SMD assembly.
Solution Approach 2:
The carrier element acts as an intermediary between the coil winding and the connection interface. It receives the loose wire ends from the coil and provides a structured platform with connection contacts that ensure planarity. This mediator allows the coil to maintain manufacturing simplicity while the carrier ensures connection precision.
2Manufacturing precision
If wire ends are bent around the housing base to achieve planarity, then connection contacts can be formed, but the device complexity increases
Solution Approach 1:
The housing structure is segmented by introducing a separate carrier element that handles the connection contact function. This separates the structural housing from the connection interface requirements, allowing the housing to remain simple while the carrier provides the necessary planarity for connection contacts.
Solution Approach 2:
The carrier element serves as an intermediary structure between the housing and the connection interface. Instead of modifying the housing itself to achieve planarity, the carrier is positioned within the housing to provide the planar connection surface, reducing the complexity of the housing structure while maintaining connection precision.
3Reliability
If additional connection elements are attached to achieve reliable connection, then connection reliability improves, but the ease of manufacture decreases
Solution Approach 1:
Multiple functions are merged into the carrier element: it provides mechanical support for the coil, holds the connection contacts, and ensures proper positioning for SMD assembly. By combining these functions into a single integrated component, the system achieves reliable connections without requiring multiple separate assembly steps or additional connection elements.
Solution Approach 2:
The carrier element is designed as a multi-functional component that simultaneously serves as a support structure for the coil, a mounting platform for connection contacts, and a positioning element for ensuring planarity. This universal component achieves reliable connections while maintaining manufacturing simplicity through its integrated design.
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
Enables reliable and efficient automatic assembly by ensuring planarity of connection contacts, simplifying the connection process, and enhancing stability through centered and securely attached components.
Implementation Method 1
An induction component with a housing (1a, 1b), in particular made of ferrite material or pressed substrate powder, in which at least one coil (7) is arranged
Data Source
Figure 1~3
Figure 4~5
Figure 6~11
AI summary
An induction coil component comprises a ferrite housing, a coil, and a coil support. The coil support acts as a holder for the coil. The coil is connected to the support, and the coil winding ends are welded to terminals on the support. The support, along with the coil, is then inserted into the housing, and the terminals on the support are used to connect the induction coil component to a printed circuit board.