Inductor Electrode Structure for Low-Resistance Coil Welding
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Solution Overview
Problem
Conventional inductors have low reliability due to weak connections between the electrode member and the coil element, leading to increased DC resistance and temperature issues when energized.
Innovation Solution
An inductor design featuring a magnetic core with a coil element and an electrode member connected via a connection portion where the drawn portion of the coil element is welded to a protruding plate portion, increasing the cross-sectional area of the connection for enhanced reliability and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal fitting is welded to the exposed tip of the coil element, then the inductor structure is simple and easy to manufacture, but the connection reliability is low and DC resistance is high
Solution Approach 1:
The electrode member transitions from a simple point-contact terminal fitting to a multi-dimensional structure with bottom plate, side plate, and protruding plate portions that extend in multiple directions. This dimensional expansion allows the electrode member to contact the coil element along its length rather than at a single tip point, increasing connection reliability while distributing electrical contact.
Solution Approach 2:
The electrode member is segmented into distinct functional portions: a bottom plate portion for mounting, a side plate portion for structural support and positioning, and a protruding plate portion for electrical connection. This segmentation allows each portion to optimize its specific function while collectively improving overall connection reliability and reducing DC resistance through distributed contact.
2Reliability
If the terminal fitting is welded to the exposed tip of the coil element, then the manufacturing process is simple, but the DC resistance is high and temperature rise occurs during operation
Solution Approach 1:
The electrode member extends in multiple dimensions with the protruding plate portion making contact with the drawn portion of the coil element. This multi-dimensional contact configuration increases the effective contact area and creates multiple parallel current paths, thereby reducing DC resistance and minimizing temperature rise during operation.
Solution Approach 2:
The drawn portion of the coil element is prepared in advance by extending it from the magnetic core to a predetermined position, creating a ready-made contact surface. This preliminary preparation allows the protruding plate portion to make optimal contact during assembly, ensuring low resistance connection before the inductor is put into operation.
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
The enhanced connection reliability and reduced DC resistance improve the overall performance and longevity of the inductor by preventing temperature rises during operation.
Implementation Method 1
the connection portion includes a first connection portion in which the drawn portion and the edge of the first protruding plate portion are welded together
Data Source
AI summary
An inductor includes: a magnetic core; a coil element including a coil portion and a drawn portion; an electrode member located on a side surface and a bottom surface; and a connection portion connecting the drawn portion and the electrode member. The electrode member includes a bottom plate portion located along the bottom surface, a side plate portion located along the side surface, and a first protruding plate portion connected to the side plate portion and protruding in a direction away from the side surface. The drawn portion extends along the side plate portion or the side surface. The first protruding plate portion includes an edge in contact with the drawn portion in an extending direction of the drawn portion. The connection portion includes a first connection portion in which the drawn portion and the edge of the first protruding plate portion are welded together.