Inductor Coil Positioning Structure for Crack-Free Molding
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Solution Overview
Problem
Conventional inductor manufacturing methods often result in poor electrical performance due to coil deformation or displacement during the molding process, leading to cracks in the magnetic core and reduced reliability.
Innovation Solution
The inductive device features a magnetic base with a core column and positioning trench, where a coil structure with bent extending sections is arranged, ensuring the coil is securely positioned and covered by a package structure, with conductive terminals exposed for improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is wound on the magnetic core with non-wound portions bent and fixed on the bottom base, then the coil structure can be formed, but the bottom base may be damaged and cracks formed therein
Solution Approach 1:
The magnetic core is divided into a bottom base and a separate core column. The core column serves as the winding support structure, while the bottom base provides electrical connection. This segmentation allows the coil to be wound on the core column without bending portions on the bottom base, eliminating cracks while maintaining manufacturability.
Solution Approach 2:
The core column acts as an intermediary structure between the bottom base and the coil. It provides the necessary support for winding the coil without requiring the bottom base to be bent or deformed, thus protecting the bottom base from damage while enabling coil formation.
2Ease of manufacture
If a molding process is performed to form a magnetic molding structure covering the magnetic core and coil, then the inductor is protected and packaged, but the coil is easily deformed or displaced due to being squeezed
Solution Approach 1:
The coil is preliminarily fixed to the core column using adhesive before the molding process. This preliminary fixation ensures the coil maintains its position and shape during the subsequent molding operation, preventing deformation or displacement while still allowing the molding process to proceed for protection and packaging.
Solution Approach 2:
The core column with its specific geometry provides a cushioning effect during the molding process. The coil, being fixed to the core column, is protected from direct squeezing forces by the core column structure, maintaining manufacturing precision while enabling the molding process.
3Stability of the object's composition
If the non-wound portions of the coil are bent and fixed on the bottom base, then the coil can be secured, but the inductor exhibits poor electrical performance and reduced reliability
Solution Approach 1:
The magnetic core is segmented into bottom base and core column, with the coil wound on the core column. The non-wound portions extend upward without being bent on the bottom base, eliminating the source of electrical performance degradation while maintaining stable coil fixation through adhesive bonding to the core column.
Data Source
AI summary
A method of manufacturing an inductive device includes: providing a magnetic base including a core column and defining a positioning trench that surrounds the core column; forming a coil structure including a coil body, a first extending section, and a second extending section, in which the coil body has a through hole, the first extending section includes a first bent portion and a first terminal portion connected thereto, and the second extending section includes a second bent portion and a second terminal portion connected thereto; arranging the coil structure in the positioning trench by sleeving the coil body around the core column; and forming a package structure to cover the magnetic base and the coil structure.