Inductor Fixing Member U-Shaped Leaf Spring Impact Resistance
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Solution Overview
Problem
Conventional inductors face issues with stress concentration and potential breakage due to excessive stress from impact loads, particularly at the slit ends of the fixing member, which can lead to structural failure.
Innovation Solution
The design incorporates a fixing member with a U-shaped fore-end portion and strategically placed slits that extend beyond the fulcrum point, distributing the load and reducing stress concentration by allowing deformation across multiple points, thereby enhancing impact resistance without increasing the case size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core is biased toward the bottom surface of the case with the elasticity produced by the leaf spring itself, then the core is retained in the case, but stress concentration occurs on the upper plate of the fixing member at the end of the slit, making it vulnerable to breakage under impact load
Solution Approach 1:
The patent divides the single leaf spring into multiple leaf springs (first leaf spring and second leaf spring) that are arranged side by side and extend from different positions on the upper plate. This segmentation distributes the elastic force and stress across multiple independent elements, preventing stress concentration at a single slit end while maintaining the biasing function against the core.
2Reliability
If multiple slits are formed to distribute stress, then impact resistance improves, but the structural complexity of the fixing member increases
Solution Approach 1:
The patent introduces dynamic elements by making the fore-end portion of the upper plate flexible through the formation of slits, allowing the plate to deform elastically under impact loads. The multiple leaf springs provide dynamic stress distribution while maintaining a relatively simple overall structure that integrates with the L-shaped fixing member configuration.
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 improved inductor design effectively absorbs impact loads, preventing stress concentration at the slit ends and ensuring the fixing member remains intact, even under significant external forces, while maintaining a compact structure.
Implementation Method 1
a fore-end portion of which is bent into a U-shape so as to define a leaf spring. In a state where the fixing member is fixed to the case, a fore-end of the leaf spring elastically push-contacts a top surface of the core and biases the core toward a bottom surface of the case
Data Source
AI summary
An inductor has a case having an opening, a core accommodated in the case, a coil wound on a part of the core and a fixing member fixed to the case. The fixing member fixes the core by contacting a top surface of the core facing the opening and elastically biasing the core toward a bottom surface of the case. The fixing member further includes a first plate portion and a first contacting portion. The first plate portion is disposed between the top surface of the core and the opening of the case and extending in parallel with the top surface of the core. The first contacting portion extends from a fore-end portion of the first plate portion so as to be U-shaped and having a distal end portion elastically push-contacting the top surface of the core.