Inductive Element Perpendicular Flat Coil Winding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional power inductors face challenges such as faulty welding, low space utilization, and inability to achieve miniaturization and thinness due to the parallel winding of flat wires, which results in high product height and susceptibility to open circuits.

Innovation Solution

The inductive element features a flat coil wound perpendicular to the magnetic core's axial direction, with a magnetic plastic package layer covering the coil and core, allowing for layer-by-layer stacking and exposure of electrodes for secure spot welding, using materials like carbonyl iron or FeSiCr powder with specific resin and stearate additives for molding and curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If flat wires are wound parallel to the middle column of the magnetic core, then the winding process is simple, but the product height becomes too high and cannot meet miniaturization requirements

Engineering Contradiction:

Improvewinding process simplicityVSAvoidproduct height

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The patent inverts the conventional winding direction by winding the flat coil perpendicular to the middle column of the magnetic core instead of parallel. This inversion allows the flat wire width to be arranged radially, enabling the product height to be determined by the wire thickness rather than width, thus achieving miniaturization while maintaining manufacturability

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent transitions from a conventional planar winding arrangement to a three-dimensional stacked layer structure where flat wires are wound perpendicular to the magnetic core and stacked in layers. This dimensional change allows efficient space utilization and reduces product height by utilizing the radial direction for wire arrangement

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If a coil is placed in an empty mold cavity and the cavity is filled with powder for pressing, then the molding process is straightforward, but the coil shifts easily and cannot be positioned accurately

Engineering Contradiction:

Improvemolding process simplicityVSAvoidcoil position accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-forming a magnetic support structure on the magnetic core before coil winding. This support structure includes positioning features that guide and secure the coil in the correct position during the molding process, preventing coil shift while maintaining process simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a magnetic support structure as an intermediary element between the magnetic core and the coil. This intermediary provides mechanical support and positioning for the coil, ensuring accurate coil placement while allowing the molding process to proceed straightforwardly

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If spot welding is used for conventional coil and power inductor on a rack, then the connection process is simple, but faulty welding and open/short circuits easily occur

Engineering Contradiction:

Improveconnection process simplicityVSAvoidwelding reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the mechanical spot welding process with an integrated magnetic support structure that mechanically secures the coil to the magnetic core. This structural integration eliminates the need for separate welding operations, reducing welding defects while maintaining connection simplicity through the support structure's inherent securing mechanism

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 configuration reduces product height, enhances reliability by preventing coil shifting, and allows for effective space utilization, achieving thinner, more reliable power inductors with improved consistency and reduced molding pressure.

Implementation Method 1

the magnetic plastic package layer is molded or is formed by means of rubber coating

Methodology Applied

Scientific EffectMolding:

Implementation Method 2

a flat coil wound on a middle column of the magnetic core

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11309117B2Inductive element and manufacturing method

Publication Date: 2022.04.19 SHENZHEN SUNLORD ELECTRONICS

AI summary

An inductive element includes a magnetic core, a flat coil wound on a middle column of the magnetic core, and a magnetic plastic package layer covering the magnetic core and the flat coil. Two electrodes connected to two pigtails of the flat coil are exposed outside of the magnetic plastic package layer. The flat coil is configured to enable a width direction of a flat wire of the flat coil to be perpendicular to an axial direction of the middle column of the magnetic core, and the flat wire is stacked layer by layer in the axial direction of the middle column. A manufacturing method for the inductive element is also disclosed herein. By using the wounding method of the flat coil of the inductive element, a height of a product may be reduced while obtaining a same DCR, so that the product is thinner.