Laminate Embedded Magnetic Core for Transformer Assembly
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Solution Overview
Problem
Manufacturing and assembling multi-portion magnetic core structures, such as EI-shaped cores, often introduce air bubbles and unfilled areas, leading to lower isolation capability and mechanical stability due to issues with solder resist application and drilling processes.
Innovation Solution
A method involving the pre-lamination of magnetic core and coil structures within a laminate structure, covered with solder resist, to embed the magnetic core and coil, thereby eliminating air bubbles and improving mechanical stability by ensuring complete encapsulation and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical drilling is performed after application of solder resist to insert the magnetic core, then the magnetic core can be positioned, but solder resist is chipped out leaving voids that reduce mechanical stability
Solution Approach 1:
The patent applies solder resist before mechanical drilling to insert the magnetic core, rather than after. This preliminary application ensures that the solder resist is already in place to protect and support the structure during drilling, preventing chipping and void formation that would compromise mechanical stability.
2Reliability
If multi-portion core structures are assembled, then isolation capability is improved, but air bubbles are introduced that reduce mechanical stability
Solution Approach 1:
The patent merges the assembly of multiple core portions with the application of solder resist and laminate materials to create a unified, void-free structure. By combining these operations and ensuring complete encapsulation with laminate and solder resist, air bubbles are prevented from being trapped between portions, maintaining both isolation capability and mechanical stability.
3Shape
If adjacent core portions are assembled, then the magnetic core structure is formed, but unfilled areas are created that reduce isolation capability
Solution Approach 1:
The patent applies laminate and solder resist materials specifically in the gaps and interfaces between adjacent core portions to ensure complete filling. This localized application of encapsulating materials targets the unfilled areas between portions, providing both mechanical support and electrical isolation without affecting the overall magnetic core structure formation.
Data Source
AI summary
A laminate embedded core and coil structure comprises a magnetic core embedded in a laminate structure that includes two types of laminates. A first laminate embeds the coils of the structure and a second laminate fills space between the magnetic core and the first laminate, as well as space below the magnetic core and lower surface of the first laminate. The first and second laminates form a laminate structure that protects and improves isolation of the magnetic components. Solder resist encloses the laminate structure, magnetic core and coils. The laminate embedded core and coil structure may be assembled on a transformer leadframe of various types using non-conductive paste.