Inductor Skeleton Structure for SMT Coil-to-PCB Mounting
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Solution Overview
Problem
Inductance devices in existing technologies face challenges in being applicable to surface mount technology, necessitating improvements for automated assembly efficiency.
Innovation Solution
An inductor skeleton structure with a pedestal and main winding part, featuring a base, fixing part, and auxiliary winding part, allowing for main and auxiliary coils to be wound and assembled in a manner that facilitates surface mount technology, with features like flush or extended welding surfaces and limit structures to prevent unwinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional inductor skeleton structures are used, then the structure is simple to manufacture, but the device cannot be applied to surface mount technology and automated assembly efficiency is low
Solution Approach 1:
The skeleton structure is divided into multiple functional parts: a base providing a fitting surface, a main winding part with a main winding groove, a fixing part for securing the main winding part, and an auxiliary winding part with a welding surface. This segmentation allows each part to be optimized for its specific function while enabling automated surface mount assembly.
Solution Approach 2:
The invention transitions from traditional three-dimensional inductor structures to a planar, two-dimensional skeleton structure that lies flat on the base. The main winding part and auxiliary winding part are arranged in the same plane as the base, with the auxiliary coil's welding surface being flush with or extending beyond the base's fitting surface, enabling surface mount technology compatibility.
2Reliability
If the auxiliary coil covers the welding surface, then electrical connectivity is improved, but the structural complexity increases
Solution Approach 1:
The auxiliary winding part is integrated directly into the skeleton structure, with its downward surface forming the welding surface that is flush with or extends beyond the base's fitting surface. This merging of the auxiliary coil structure with the skeleton eliminates the need for separate mounting components and simplifies the overall device while ensuring reliable electrical connectivity.
Solution Approach 2:
The auxiliary winding part serves multiple functions: it provides the auxiliary coil winding structure, creates the welding surface for PCB mounting, and contributes to the overall structural stability. This multi-functionality reduces the need for additional components and simplifies the device complexity.
3Stability of the object's composition
If the main winding part is fixed on the base, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The fixing part is pre-formed as an integral component of the skeleton structure, designed to receive and secure the main winding part in a predetermined position. This preliminary preparation of the fixing structure simplifies the assembly process and maintains structural stability without significantly increasing manufacturing complexity.
Data Source
AI summary
An inductor skeleton structure includes a pedestal and a main winding part. The pedestal includes a base, a fixing part and an auxiliary winding part, the fixing part is disposed on the base, and the auxiliary winding part is extended away from the base from a side surface; the main winding part has a main winding groove; the main winding part is fixed on a side of the base by the fixing part; the auxiliary winding part is used for winding an auxiliary coil capable of covering at least a portion of the welding surface; and the auxiliary coil is flush with or beyond the fitting surface.