Inductor Core Compaction With Intermittent Green Compact Joints
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Solution Overview
Problem
Existing inductor element manufacturing methods face challenges in achieving high density and uniformity, leading to uneven density and reduced withstand voltage due to the collapse of small-hardness parts during re-pressing, which affects DC superposition characteristics and inductance.
Innovation Solution
A method involving preliminary compression molding of magnetic powder and resin granules at high pressure to form green compacts, followed by integration with a coil insert member to create an inductor element with intermittent joint interfaces, allowing for improved pressure transmission and reduced distortion, enhancing withstand voltage, inductance, and DC superposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If re-pressing is performed to increase density for improving DC superposition characteristics, then density increases, but the shape of small-hardness parts collapses and pressure transmission becomes insufficient, causing uneven density
Solution Approach 1:
The patent applies preliminary compression molding at a relatively low pressure (2.5×10² to 1×10³ MPa) before the final re-pressing step. This preliminary action creates green compacts with sufficient structural integrity, preventing shape collapse during subsequent high-pressure re-pressing while still allowing for adequate pressure transmission to achieve uniform density and improve DC superposition characteristics.
2Quantity of substance
If high pressure is applied during re-pressing to increase density, then density increases, but coil film breaks or inner wall of die and magnetic powder surface are rubbed, decreasing withstand voltage
Solution Approach 1:
The patent performs preliminary compression molding at a relatively low pressure (2.5×10² to 1×10³ MPa) before the final re-pressing step. This preliminary action creates green compacts with sufficient structural integrity, preventing shape collapse during subsequent high-pressure re-pressing while still allowing for adequate pressure transmission to achieve uniform density and improve DC superposition characteristics.
3Quantity of substance
If re-pressing is performed to improve DC superposition characteristics, then density increases, but the pressed powders are joined with insufficient pressure transmission, decreasing inductance
Solution Approach 1:
The patent performs preliminary compression molding at a relatively low pressure (2.5×10² to 1×10³ MPa) before the final re-pressing step. This preliminary action creates green compacts with sufficient structural integrity, preventing shape collapse during subsequent high-pressure re-pressing while still allowing for adequate pressure transmission to achieve uniform density and improve DC superposition characteristics.
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 method results in inductor elements with improved withstand voltage, inductance, and DC superposition characteristics by maintaining density and preventing positional and shape distortions, while reducing the risk of coil film breakage and surface abrasion.
Implementation Method 1
obtaining a plurality of preliminary green compacts by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×10² to 1×10³ MPa
Data Source
AI summary
A method of manufacturing an inductor element includes preparing an insert member including a winding portion where a conductor is wound in a coil shape. A plurality of preliminary green compacts is obtained by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×102 to 1×103 MPa. The insert member and the plurality of preliminary green compacts are integrated so that a joint interface of the plurality of preliminary green compacts is formed intermittently.