Inductor Electrode Locking Structure for Vibration Reliability
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Solution Overview
Problem
Conventional inductors face reliability issues due to low connection reliability between the electrode member and the magnetic core, particularly under vibration, leading to disconnection and reduced performance.
Innovation Solution
The inductor design includes a magnetic core with a projection and recess mechanism, combined with a plate-shaped electrode member featuring a locking portion that securely connects to the magnetic core, enhancing the connection reliability through increased cross-sectional area and mechanical locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal fitting is attached to the main body using an adhesive, then the inductor can be manufactured with simple assembly, but the connection reliability between the electrode member and magnetic core is low under vibration
Solution Approach 1:
The connection structure is segmented into multiple functional components: a projection extending from the magnetic core, a recess receiving the projection, and a locking portion with an opening. This segmentation allows each component to perform a specific function (positioning, receiving, and mechanical locking) thereby achieving reliable vibration resistance without requiring complex assembly procedures or adhesives.
Solution Approach 2:
The projection is pre-formed on the magnetic core and the recess is pre-formed to receive it. This preliminary action ensures that when the electrode member is assembled, the locking portion automatically engages with the projection through the opening, creating a pre-established mechanical lock that prevents disconnection under vibration before the product is put into service.
2Reliability
If the terminal fitting is welded to the coil element, then electrical connection is achieved, but the overall connection reliability remains low due to adhesive attachment to the magnetic core
Solution Approach 1:
The invention merges the mechanical attachment function and the electrical connection function into a single integrated locking mechanism. The locking portion that mechanically secures the electrode member to the magnetic core also serves as the electrical connection point, eliminating the need for separate adhesive attachment and welding operations, thereby improving reliability while maintaining manufacturing simplicity.
Solution Approach 2:
The locking portion with the opening is designed to self-align and self-lock onto the projection during assembly. The structure automatically performs the connection function without requiring external adhesive application or complex welding procedures, making the manufacturing process simpler while achieving high connection reliability.
3Reliability
If a simple adhesive attachment is used, then manufacturing is simple, but the electrode member can disconnect under vibration leading to reduced performance
Solution Approach 1:
The locking portion is nested within the recess and locks onto the projection, creating a nested structural arrangement. The opening of the locking portion receives the projection, and the locking portion itself is received by the recess, forming a nested configuration that provides robust vibration resistance through interlocking geometry rather than through complex multi-component structures.
4Device complexity
If the connection structure is simplified using only adhesive, then device complexity is reduced, but reliability under vibration deteriorates
Solution Approach 1:
The connection structure employs asymmetric geometry where the projection has a specific shape that fits into the recess with the locking portion's opening. This asymmetric design creates a directional mechanical lock that is simple in form but effective in function, providing vibration resistance without requiring symmetric or complex multi-faceted structures.
Data Source
AI summary
An inductor includes: a magnetic core that includes side surfaces; a coil element that includes a drawing portion which is drawn from the side surface to the outside of the magnetic core; and an electrode member that is plate-shaped, disposed on the side surface and a bottom surface, and electrically connected to the coil element, the magnetic core includes a projection that protrudes in a direction perpendicular to at least one of the side surface or a top surface and a recess that surrounds the projection and is recessed more inward of the magnetic core than the projection, and the electrode member includes a locking portion that includes an opening which penetrates, according to the projection, the electrode member in the direction of thickness of the electrode member, and the locking portion enters the recess to be locked to a locking surface connecting the projection and the recess.