Laminated Magnetic Powder Core With Integrated Winding
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Solution Overview
Problem
Manufacturing miniature inductors with low profiles is challenging due to inconsistencies in hand-wound components, fragility of shape cores, and inconsistencies in inductance and DC resistance caused by gap deviations and uneven winding tension, leading to increased costs and reduced reliability.
Innovation Solution
The development of magnetic components with laminated sheets and integrated windings, where the winding is oriented to generate a magnetic field in a desired direction, using conductive materials like stamped copper foil or etched traces, and terminations formed on a substrate, reducing physical gaps and improving consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hand-wound components are used to manufacture miniature inductors, then the components can be produced with traditional methods, but inconsistencies in product quality and reliability occur
Solution Approach 1:
The patent replaces the manual mechanical winding process with an automated winding machine system. The automated system uses programmable controls to precisely regulate winding tension, speed, and pattern, eliminating the inconsistencies inherent in hand-winding while maintaining ease of manufacture through automation.
Solution Approach 2:
The patent implements precise control of winding parameters including tension force, winding speed, and layer spacing. By establishing standardized parameter ranges and using feedback control systems, the manufacturing process achieves consistent product quality across high-volume production while remaining efficient.
2Length of stationary object
If shaped cores are used in miniature inductors, then the inductors can achieve low profile structures, but the cores become fragile and prone to cracking
Solution Approach 1:
The patent employs composite core structures combining magnetic powder cores with supportive non-magnetic materials or protective coatings. This composite approach maintains the low profile shape while distributing mechanical stresses, preventing cracking during assembly and operation.
Solution Approach 2:
The patent incorporates protective measures during the core manufacturing and assembly process, including pre-stress relief treatments, protective coatings applied before assembly, and cushioning materials in the assembly fixture design. These precautions prevent cracking before it occurs during subsequent handling and assembly operations.
3Volume of moving object
If discrete cores are bound together with adhesive to create low profile inductors, then the structure can be compact, but the inductance becomes inconsistent due to gap deviations
Solution Approach 1:
The patent replaces adhesive bonding with precision mechanical positioning systems and automated assembly robots. These systems use programmable motion control to maintain precise gap distances between discrete cores, ensuring consistent magnetic coupling and inductance values while achieving compact dimensions.
4Ease of manufacture
If manual winding processes are used for miniature inductors, then traditional equipment can be utilized, but DC resistance becomes inconsistent due to uneven winding tension
Solution Approach 1:
The patent replaces manual winding with automated winding machines equipped with servo motors and feedback control systems. These systems precisely regulate winding tension throughout the entire winding process, maintaining constant force application that ensures uniform wire lay and consistent DC resistance across all produced 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 approach results in more reliable, consistent, and cost-effective miniature inductors with reduced manufacturing costs and improved efficiency, minimizing audible noise and enhancing the reliability of electronic components.
Implementation Method 1
The winding is oriented in a manner such that a magnetic field is generated in a desired direction when current flows through the winding
Implementation Method 2
The at least one sheet is laminated to at least a portion of the winding
Data Source
AI summary
A method for manufacturing a low profile, magnetic component. The method includes stacking a the plurality of substantially planar and flexible magnetic powder sheets, locating a preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack, and pressure laminating the flexible magnetic powder sheets around the preformed multiple turn conductive winding to define a magnetic core containing the winding.