Lead-Frame and Magnetic Core Assembly for Terminal Coplanarity
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Solution Overview
Problem
The independent lead-frame structures for metal terminal assemblies result in poor coplanarity and positioning, leading to welding defects and potential short circuits.
Innovation Solution
A combined lead-frame and magnetic core structure where the lead-frame has coplanar terminal assemblies and protecting feet, and the magnetic core has convex beds on flange portions to enhance positioning and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If independent lead-frame structures are used for metal terminal assemblies, then manufacturing simplicity is maintained, but coplanarity and positioning of terminals deteriorate
Solution Approach 1:
The patent combines two independent lead-frame structures into a single integrated lead-frame structure that supports both metal terminal assemblies. This merging approach maintains manufacturing simplicity while achieving precise coplanarity and positioning of terminals across both assemblies, resolving the contradiction between ease of manufacture and manufacturing precision.
2Device complexity
If independent lead-frame structures are used, then structural independence is maintained, but welding quality deteriorates due to poor positioning
Solution Approach 1:
The integrated lead-frame structure combines previously independent structures while maintaining functional separation of metal terminal assemblies. This ensures proper positioning and coplanarity of terminals, thereby improving welding quality and reliability without excessive increase in device complexity.
3Adaptability or versatility
If independent lead-frame structures are used, then assembly flexibility is maintained, but short circuit risk increases due to poor positioning
Solution Approach 1:
The combined lead-frame structure provides a unified support platform that ensures accurate positioning of metal terminals, reducing the risk of short circuits. The design maintains assembly flexibility through modular metal terminal assemblies while eliminating positioning errors that could lead to harmful short circuit conditions.
Data Source
AI summary
A lead-frame structure and a magnetic core structure combined with lead-frame structure are described. The lead-frame structure includes a frame, a first metal terminal assembly, and a second metal terminal assembly. The frame includes a first assembling portion and a second assembling portion spaced apart from each other. The first metal terminal assembly is formed on the first assembling portion and includes first terminals. The second metal terminal assembly is formed on the second assembling portion and includes second terminals. A top surface of each first terminal, a top surface of each second terminal, a top surface of the first assembling portion, and a top surface of the second assembling portion are coplanar. The magnetic core structure includes a body combined with the above-described lead-frame structure. The body provides convex beds to improve a positional accuracy of the first terminals and the second terminals.