Inductor Coil Trench Layout to Prevent Molding Displacement
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Solution Overview
Problem
Conventional inductor manufacturing methods often result in poor electrical performance due to coil deformation and displacement during the molding process, leading to cracks in the magnetic core and reduced reliability.
Innovation Solution
The inductive device features a magnetic base with a core column and positioning trench, where a coil structure with bent extending sections is arranged, ensuring the coil is securely positioned and covered by a package structure, with conductive terminals exposed for improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is wound on the magnetic core with non-wound portions bent and fixed on the bottom base, then the coil can be assembled to the magnetic core, but the bottom base may be damaged and cracks formed therein
Solution Approach 1:
The magnetic core is segmented into a bottom base and a separate core column. The core column serves as the mounting structure for the coil, while the bottom base provides electrical connection. This segmentation prevents the coil from being directly bent and fixed on the bottom base, thereby avoiding cracks in the bottom base while maintaining ease of assembly.
2Ease of manufacture
If a molding process is performed to form a magnetic molding structure covering the magnetic core and coil, then the components are enclosed and protected, but the coil is easily deformed or displaced due to being squeezed
Solution Approach 1:
The coil is pre-assembled on the core column with its non-wound portions extending in a predetermined direction before the molding process. The core column acts as a support structure that maintains the coil's position and shape during molding. This preliminary arrangement ensures the coil is not deformed or displaced when the magnetic molding structure is formed, while still allowing the molding process to enclose and protect the components.
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 design enhances the reliability and electrical performance of the inductor by preventing coil displacement and deformation, maintaining structural integrity and increasing contact areas for better bonding strength.
Implementation Method 1
An inductor is a passive device that has been widely used in a circuit design
Data Source
AI summary
An inductive device and a method of manufacturing the same are provided. The inductive device includes a magnetic base, a coil structure, and a package structure. The magnetic base includes a bottom plate, a core column, and a lateral wall defining a positioning trench. The coil structure includes a coil body, a first extending section, and a second extending section. The coil body disposed in the positioning trench surrounds the core column. The first extending section includes a first bent portion and a first terminal portion connected at a first connecting point. The second extending section includes a second bent portion and a second terminal portion connected at a second connecting point. A shortest distance between a first imaginary connection line defined between the first and second connecting points and a central axis of the core column is less than a minimum outer radius of the coil body.