Induction Component Production via Ferromagnetic Substrate Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing induction components are inefficient and do not allow for the simultaneous mass production of identical or varied induction components with different coil configurations.
Innovation Solution
A method where multiple coils are arranged in a block made of a pressed ferromagnetic substrate, with the substrate powder filled inside and then pressed to create a block, which is later divided into individual components, allowing for the production of identical or varied induction components with embedded coils and continuous wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple coils are produced individually using traditional methods, then each coil can be precisely manufactured, but production efficiency is low and mass production is not achieved
Solution Approach 1:
The production process is segmented into distinct stages: coil winding on separate jigs, substrate preparation, assembly into mold, pressing, and cutting. This allows each stage to be optimized independently while enabling mass production through simultaneous processing of multiple coils
Solution Approach 2:
Multiple coils are combined into a single mold cavity arrangement, allowing simultaneous pressing and curing of multiple induction components in one production cycle, thereby achieving mass production while maintaining individual coil precision
2Productivity
If coils are arranged in a block and pressed together, then mass production is achieved, but the coil connections require additional termination steps
Solution Approach 1:
Coils are pre-wound on jigs with pins that extend through the substrate, establishing connection points before the pressing process. This preliminary arrangement simplifies subsequent termination steps as the wire paths are already defined and accessible
3Stability of the object's composition
If substrate powder is pressed around arranged coils, then a unified block structure is created, but the pressing process becomes more complex
Solution Approach 1:
The substrate powder acts as an intermediary material that binds the coils together into a unified block structure. The powder is applied around the pre-arranged coils and then pressed to create a stable composite structure that maintains individual coil integrity while forming a cohesive assembly
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 efficient and simultaneous production of a large number of induction components with different coil configurations, improving production efficiency and allowing for customizable inductance by using different substrate powders with varying magnetic properties.
Implementation Method 1
the substrate powder is then pressed. This creates a block with a large number of coils
Implementation Method 2
The winding ends in the end face of the inductor created in this way are contacted by sputtering
Data Source
Figure 1~4
Figure 5~8
Figure 9~11
AI summary
The invention relates to a method for producing induction components, each containing a coil, in order to wind the coils on a wire winding plate containing a plurality of wire winding pins arranged in rows and columns, using a continuous wire for a number of coils. The template provided with the coils is then pressed in a moulding press together with ferromagnetic powder substrate, which surrounds the coils. After removing the template, the inner regions of the coils are again provided with powder substrate in a moulding press, and pressed. Finally, the connections are contacted, and the blocks are broken up into individual induction components, each containing a coil.