Integrated Trans-Inductor Winding for Precise PCB Assembly
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Solution Overview
Problem
Traditional trans-inductor architectures face challenges with high manufacturing failure rates due to complex assembly processes, alignment issues, and low yield rates, leading to problems like hi-pot failure, coplanarity failure, and winding centering failure.
Innovation Solution
An integrated trans-inductor design featuring a magnetic core with an integrated winding, where the inner and outer windings are molded together using plastic, ensuring precise alignment and coplanarity, simplifying the manufacturing process and reducing assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional trans-inductor architecture with separate windings is used, then manufacturing flexibility is maintained, but manufacturing failure rate increases due to complex assembly processes and alignment issues
Solution Approach 1:
The patent combines the inner winding and outer winding into a single integrated winding component manufactured as one piece using injection molding. This merging eliminates the need for separate assembly of multiple winding components, thereby simplifying the manufacturing process and reducing alignment issues that cause manufacturing failures, while simultaneously improving reliability by eliminating assembly-related defects.
Solution Approach 2:
The patent performs preliminary action by pre-integrating the inner and outer windings into a single molded component before assembly with the magnetic core. This preliminary integration ensures precise alignment and coplanarity are built into the component itself, preventing alignment issues during final assembly and reducing manufacturing failure rates.
2Productivity
If integrated winding design is used, then manufacturing efficiency improves and failure rates reduce, but device complexity increases due to molding process requirements
Solution Approach 1:
The patent replaces the mechanical assembly process of separately mounting inner and outer windings with an injection molding process that integrates both windings into a single component. This substitution eliminates multiple mechanical assembly steps, improves manufacturing efficiency, and reduces failure rates while the molding process itself manages the complexity through automated manufacturing.
3Manufacturing precision
If traditional separate winding assembly is used, then manufacturing flexibility is maintained, but coplanarity and alignment precision deteriorate
Solution Approach 1:
The patent merges the inner and outer windings into a single integrated component manufactured via injection molding. This merging ensures that both windings are precisely positioned relative to each other during the molding process, achieving high coplanarity precision without requiring complex assembly processes to align separate 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
The integrated design significantly improves manufacturing efficiency, reduces failure rates, and enhances power density and current handling capability, while maintaining a smaller footprint on circuit boards.
Implementation Method 1
An inductor, also called a coil, choke, or reactor, is a passive two-terminal electrical component that stores energy in a magnetic field when electric current flows through it
Implementation Method 2
The integrated winding may have an inner winding and an outer winding integrated using plastic molding prior to the assembly
Data Source
AI summary
In one embodiment, a surface mount electromagnetic component for multi-phase electrical power circuitry implemented on a circuit board includes a first magnetic core, a second magnetic core structure, and an integrated winding. The integrated winding includes an inner winding and an outer winding, wherein the integrated winding is constructed by molding the inner winding and the outer winding, wherein the inner winding is electrically isolated from the outer winding, wherein the inner winding is nested in the outer winding, wherein the inner winding defines a first inverted U-shaped main winding portion, wherein the first inverted U-shaped main winding portion includes a first top section and first vertical legs perpendicular to the first top section, and wherein the outer winding defines a second inverted U-shaped main winding portion, wherein the second inverted U-shaped main winding portion includes a second top section and second vertical legs perpendicular to the second top section.