Inductor Fixation Member for Core Positioning
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Solution Overview
Problem
Existing inductors with closed magnetic paths require additional workload and specialized jigs to maintain positional accuracy, leading to reduced productivity due to the inability of simple tape winding to prevent relative positional shifts between cores and coils.
Innovation Solution
An inductor design featuring a pair of magnetic members with rod-like insertion parts and a sheet-formed fixation member that binds across the magnetic members and the main body, forming a closed magnetic path, thereby fixing the relative positions and reducing the need for specialized jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a simple winding of the tape is used to fix the cores, then the workload is reduced and productivity is improved, but the relative positional shift between the coil and the core cannot be prevented
Solution Approach 1:
The fixation method is segmented into two distinct functions: the tape performs simple binding for basic positioning, while the dedicated fixation member (clamp or adhesive) provides precise positional fixation. This segmentation allows each component to specialize in one aspect, maintaining simplicity while achieving precision.
Solution Approach 2:
A dedicated fixation member acts as an intermediary between the simple tape winding and the final positional accuracy requirement. This intermediary component (clamp or adhesive) bridges the gap by providing the additional positional control that the tape alone cannot achieve.
2Manufacturing precision
If additional steps and specialized jigs are used to fix the relative positional relation, then the positional accuracy is improved, but the workload increases and productivity decreases
Solution Approach 1:
The complex positioning function is extracted from the simple tape winding process and assigned to a dedicated fixation member. This extraction allows the tape to remain simple while the specialized fixation component handles the precision requirement, avoiding the need for complex jigs.
Solution Approach 2:
The fixation member (particularly the adhesive type) provides self-aligning and self-fixing capabilities, eliminating the need for external jigs or complex positioning mechanisms. The adhesive naturally conforms to the surfaces and maintains positional accuracy without additional equipment.
3Stability of the object's composition
If multiple separate components are used to fix the magnetic members and main body, then the positional stability is improved, but the device complexity increases
Solution Approach 1:
The fixation member combines multiple functions into a single component: it simultaneously fixes the magnetic members to each other and secures the assembly to the main body. This merging reduces the number of separate components needed while maintaining positional stability.
Solution Approach 2:
The fixation member is designed with multi-functionality, serving both to bond magnetic members together and to attach the entire magnetic assembly to the main body. This universal component eliminates the need for separate fixation elements for each function.
Data Source
AI summary
An inductor (100) includes a pair of magnetic members (cores (10, 20)), a main body having coils (71, 72), and a sheet-formed fixation member (60), wherein the fixation member (60) is bound across the cores (10, 20) and the main body, to thereby fix the cores (10, 20) which configure a closed magnetic path, and to thereby fix at least one of the cores (10, 20) to the main body.