Integrated Lead-Frame Structure for Coplanar Terminal Positioning
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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 metal terminal assemblies are formed on a shared frame with coplanar surfaces and assisted by convex beds on the magnetic core's flange portions, along with protecting feet, to enhance positioning and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If independent lead-frame structures are used for metal terminal assemblies, then the structure is simple and easy to manufacture, but the coplanarity and positioning of metal terminals deteriorate, leading to welding defects
Solution Approach 1:
The patent merges two independent lead-frame structures into a single integrated lead-frame structure that supports both metal terminal assemblies. This integration ensures coplanarity between the first and second metal terminal assemblies by providing a common reference plane, while maintaining manufacturing simplicity through the unified structure design.
2Manufacturing precision
If independent lead-frame structures are used for metal terminal assemblies, then the manufacturing process is simple, but positioning accuracy deteriorates, resulting in potential short circuits
Solution Approach 1:
The patent combines positioning functions for both metal terminal assemblies into a single integrated lead-frame structure. This unified structure provides consistent positioning references that improve positioning accuracy and prevent short circuits, while the integration actually simplifies the manufacturing process by reducing the number of separate components to assemble.
3Reliability
If a combined lead-frame structure is used to improve coplanarity and positioning, then welding quality improves, but the structure becomes more complex
Solution Approach 1:
The patent integrates multiple functions (support, positioning, coplanarity reference) into a single lead-frame structure, which improves welding quality by ensuring proper alignment of metal terminals. The merging of functions into one structure actually reduces overall complexity compared to using multiple separate components.
Data Source
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AI summary
A lead-frame structure (10) and a magnetic core structure (20) combined with lead-frame structure (10) are described. The lead-frame structure (10) includes a frame (11), a first metal terminal assembly (12), and a second metal terminal assembly (13). The frame (11) includes a first assembling portion (111) and a second assembling portion (112) spaced apart from each other. The first metal terminal assembly (12) is formed on the first assembling portion (111) and includes first terminals (121). The second metal terminal assembly (13) is formed on the second assembling portion (112) and includes second terminals (131). A top surface (121T) of each first terminal (121), a top surface (131T) of each second terminal (131), a top surface (111T) of the first assembling portion (111), and a top surface (112T) of the second assembling portion (112) are coplanar. The magnetic core structure (20) includes a body (21) combined with the above-described lead-frame structure (10). The body (21) provides convex beds (2122) to improve a positional accuracy of the first terminals (121) and the second terminals (131).