Inductor Coil-Base Structure for Flexible Core Sizing
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Solution Overview
Problem
Conventional inductor designs face limitations in flexibility and increased fabrication costs due to the need for varying magnetic core sizes and coil dimensions, which restricts design freedom and complicates the shaping of smaller magnetic cores.
Innovation Solution
The inductive device features a coreless magnetic base with an assembling surface and defined arrangement region, where a coil structure with extending sections is assembled, and a package structure with a magnetic molding main body fills into the coil body's through hole, allowing for flexible design without increasing fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the coil size is adjusted to satisfy different product requirements, then the design flexibility is improved, but different magnetic cores of different sizes must be fabricated which significantly increases fabrication cost
Solution Approach 1:
The magnetic core is designed with a universal structure that can accommodate coils of different sizes through a coil receiving portion with adjustable dimensions. The core column's cross-sectional shape matches the coil body's cross-sectional shape, allowing the same core structure to support various coil configurations without requiring multiple different core sizes, thereby maintaining design flexibility while controlling fabrication costs.
Solution Approach 2:
The patent changes the parameters of the coil receiving portion (length and width) to accommodate different coil sizes while keeping the overall magnetic core structure the same. By adjusting only the coil receiving portion dimensions rather than the entire core size, the design achieves adaptability for different products without significantly increasing fabrication complexity or cost.
2Volume of moving object
If the size of the inductor is reduced, then the miniaturization requirement is satisfied, but the shaping of the core column becomes more difficult
Solution Approach 1:
The magnetic core is segmented into distinct functional portions: a base portion and a core column portion with a coil receiving portion. This segmentation allows the core column to be designed with optimized dimensions and shapes that are easier to manufacture, even at reduced sizes. The core column's cross-sectional shape is specifically designed to match the coil body, simplifying the shaping process while maintaining the required miniaturization.
3Device complexity
If a conventional magnetic core structure is used, then the structural simplicity is maintained, but the coil size is limited to the size of the core column which restricts design freedom
Solution Approach 1:
The patent introduces a coil receiving portion with dimensions that can be independently adjusted in length and width, adding dimensional flexibility to the conventional core structure. This allows the coil body to have different cross-sectional shapes and sizes that match the coil receiving portion, providing design freedom without significantly complicating the overall magnetic core structure.
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
This configuration enables more flexible inductor design and reduces fabrication and development costs by allowing coil size adjustments without requiring different magnetic core sizes, while maintaining structural integrity and ease of assembly.
Implementation Method 1
An inductor is a passive device that has been widely used in a circuit design
Implementation Method 2
a magnetic base, a coil structure, and a package structure. The magnetic base has an assembling surface
Data Source
AI summary
An inductive device and a manufacturing method thereof are provided. The inductive device includes a magnetic base, a coil structure, and a package structure. The magnetic base has an assembling surface, and an arrangement region is defined thereon. The coil structure is assembled to the magnetic base and includes a coil body, a first extending section, and a second extending section. The coil body has a though hole corresponding in position to the arrangement region, and the first and second extending sections both extend from the coil body toward the magnetic base and are wound on the magnetic base. The package structure covers the magnetic base and the coil structure. The package structure includes a magnetic molding main body, and a portion of the magnetic molding main body fills into the through hole of the coil body and is connected to the magnetic base.