Magnetic Component Assembly Thinning for Pin Spacing Control
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Solution Overview
Problem
The existing magnetic component assemblies face challenges in miniaturization and mass production due to dimensional errors between the magnetic core and the frame, leading to risks of fracturing during pressing operations and poor electroplating in subsequent embedded processes.
Innovation Solution
The proposed solution involves thinning the magnetic assembling body to control the spaced distance between the pins of the windings and the thinned plane, thereby reducing the impact of dimensional errors and improving the product yield by minimizing the risk of poor electroplating and reducing the connection path between the magnetic component and the power device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the magnetic core and frame are assembled with pressing operation to form double-sided pins, then the magnetic component assembly achieves miniaturization and mass production capability, but dimensional errors between the magnetic core and frame cause fracturing risk and poor electroplating
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the magnetic core before assembling with the frame. These recesses are designed with specific dimensions and positions to accommodate the frame structure, ensuring that when the frame is pressed into place, the magnetic core and frame achieve precise alignment and fit without dimensional errors causing fracturing or poor electroplating. This preliminary preparation eliminates the need for post-assembly adjustments and ensures consistent manufacturing quality.
2Reliability
If the height of the frame is increased to accommodate dimensional variations, then the risk of poor electroplating is reduced, but the connection path between the magnetic component and power device becomes longer increasing loss
Solution Approach 1:
The patent applies parameter changes by precisely controlling the dimensions of the recesses in the magnetic core and the corresponding dimensions of the frame. By optimizing these geometric parameters, the patent achieves the optimal balance where the frame fits precisely into the recesses without excessive height, ensuring good electroplating quality while maintaining short connection paths between the magnetic component and power device, thus minimizing connection loss.
3Ease of manufacture
If the magnetic core height is reduced to match the frame height for flat structure, then the pressing operation becomes easier, but the magnetic core is at risk of fracturing during pressing
Solution Approach 1:
The patent applies local quality by creating localized recesses in specific regions of the magnetic core rather than uniformly reducing the entire magnetic core height. These recesses are strategically positioned where the frame needs to interface with the magnetic core, providing local accommodation for the frame structure while maintaining the overall structural integrity and sufficient height of the magnetic core body, thus preventing fracturing during pressing operation.
Data Source
AI summary
A magnetic component assembly and a manufacturing method thereof are disclosed. The magnetic component assembly includes a magnetic component and a peripheral structure. The magnetic component includes a magnetic core and a winding. The winding is embedded in the magnetic core, and passes through the top surface or the bottom surface of the magnetic core to form a pin. The peripheral structure is disposed adjacent to a peripheral side of the magnetic core. The magnetic component and the peripheral structure are combined to form a magnetic assembling body. The manufacturing method thereof includes a step of thinning the top surface or the bottom surface of the magnetic assembling body through a thinning process. The manufacturing method thereof includes another step of thinning the top surface or the bottom surface of the magnetic core through a thinning process, or thinning the pin through the thinning process.