Integrated Power Inductor Assembly for Compact Battery Interface
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Solution Overview
Problem
Current power inductors for electric power steering systems require a multi-piece construction, leading to increased costs and susceptibility to stress due to the need for separate components for the power coil and terminal connections, lacking a one-piece vehicle battery interface integrated into the coil.
Innovation Solution
A power inductor with a base structure, a power coil integrated into the base, and a connector terminal extending for connection to a circuit board, along with a power terminal for connection to a power source, forming a single assembly that includes a housing with extended segments for additional connections, allowing for a more integrated and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-piece construction is used for power inductor, then connection flexibility is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the power coil and connector terminal into a single integrated power inductor component. The connector terminal is directly formed as part of the coil structure, eliminating the need for separate connection pieces while maintaining electrical functionality. This merging reduces device complexity and component count while preserving connection flexibility through the integrated design.
2Ease of manufacture
If separate power terminal and coil are used, then manufacturing simplicity is improved, but stress resistance worsens
Solution Approach 1:
The connector terminal is integrated directly into the coil structure, creating a unified component that eliminates stress concentration points at connection interfaces. This integration improves stress resistance and reliability while the manufacturing process maintains simplicity through single-component fabrication.
3Volume of moving object
If integrated power terminal and coil are used, then packaging efficiency is improved, but device complexity increases
Solution Approach 1:
The integration of the power terminal and coil into a single compact component reduces the overall volume required for the power pack assembly. The unified structure eliminates the need for separate mounting spaces and connection interfaces, achieving space efficiency without requiring complex multi-component integration schemes.
Data Source
AI summary
A power inductor for an electric power steering system includes a base structure. The power inductor also includes a power coil secured to the base structure. The power inductor further includes a connector terminal extending from the base structure for connection to a circuit board. The power inductor yet includes a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.