Inductor with Integral Moulding and Segmented Core
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Solution Overview
Problem
Current die-casting inductors face limitations in structural layout design and material combination, failing to meet demands for high efficiency and low loss, necessitating an improved induction component with enhanced manufacturability and performance.
Innovation Solution
The inductor is manufactured using an integral moulding power casting process, where the electrodes of a prefabricated inner core are encased in an outer layer, and a separated-type core shaft is used, allowing for different material combinations to vary electrical parameters, thereby improving firmness and reducing quality risks while saving manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional die-casting inductors are used, then manufacturing process is simple, but structural layout design is limited and material combination is restricted
Solution Approach 1:
The inductor is divided into separate components: an inner core with pre-formed electrodes and an outer encasing layer. This segmentation allows independent optimization of each component's structure and material properties, enabling greater design flexibility and material combination options without significantly complicating the overall manufacturing process.
Solution Approach 2:
The patent employs composite material construction by combining different materials for the inner core and outer encasing layer. This allows selection of optimal material combinations to achieve desired electrical and mechanical properties, breaking through the material combination limitations of conventional single-material die-casting inductors.
2Reliability
If electrodes are not encased in outer layer, then manufacturing process is simpler, but electrode firmness is insufficient and quality risk increases
Solution Approach 1:
The manufacturing process merges the electrode formation and encasing operations into an integrated process. The inner core with electrodes is directly encased in the outer layer during the same manufacturing cycle, eliminating separate electrode attachment steps and reducing quality risks while maintaining ease of manufacture.
Solution Approach 2:
The electrodes are pre-formed on the inner core before the encasing process. This preliminary action ensures proper electrode positioning and firmness are achieved during the encasing operation, improving reliability without requiring complex post-processing steps.
3Adaptability or versatility
If multiple electrical parameter variations are needed, then design flexibility improves, but device complexity and volume increase
Solution Approach 1:
Different material compositions and properties are applied locally to specific regions of the inner core and outer encasing layer. This allows tailoring of electrical parameters (such as permeability, resistance, and inductance) in specific areas without changing the overall inductor volume, enabling multiple electrical parameter variations within the same physical footprint.
Data Source
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AI summary
The invention relates to a novel inductor, comprising a mounted inner core, electrodes and an outer encasing layer, wherein the mounted inner core comprises an enameled coil and a core shaft, and the mounted inner core and the electrodes are buried into the centre of the outer encasing layer. The novel inductor has the advantages that manufacturability and performances of the inductor can be improved.