Magnetic Component Integrated Bobbin Injection Molding
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Solution Overview
Problem
Conventional magnetic components face challenges in assembly complexity, large tolerances, poor electrical characteristics, size limitations, and increased costs due to the assembly of multiple components, which complicates the control of screw fastening positions and results in inefficient energy storage and conversion.
Innovation Solution
The use of an injection molding process to form molding bobbins covering core sets, allowing for the assembly of core components into pillars with controlled gaps to absorb tolerances and reduce length differences, thereby improving the precision and stability of the magnetic component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (bobbin, core, spacer) are assembled by adhesion, then the magnetic component can be formed, but the assembly process becomes complicated and tolerance accumulation increases
Solution Approach 1:
The patent combines the bobbin and core into a single integrated component formed by injection molding. The bobbin is molded directly over the core set, eliminating the need for separate assembly steps and adhesion processes. This merging of components reduces assembly complexity while maintaining or improving electrical characteristics through better integration and reduced tolerance accumulation.
2Manufacturing precision
If multiple components are assembled by adhesion, then the magnetic component can be formed, but the overall tolerance becomes too large and screw fastening position control becomes difficult
Solution Approach 1:
By integrating the bobbin and core into a single molded component, the patent eliminates multiple interfaces where tolerance accumulation occurs. The injection molding process produces a monolithic structure with consistent dimensional tolerances, making screw fastening positions easier to control and locate precisely without the complexity of assembling multiple separate components.
3Ease of manufacture
If conventional assembly methods are used, then the magnetic component can be manufactured, but the process time increases and cost increases
Solution Approach 1:
The patent performs the bobbin formation and core coverage in a single preliminary injection molding action, rather than through multiple sequential assembly steps. This preliminary action of molding the bobbin directly over the pre-positioned core set consolidates multiple operations into one, reducing process time and associated labor costs while maintaining manufacturing feasibility.
4Volume of moving object
If conventional assembly methods are used, then the magnetic component can be manufactured, but the amount of potting glue increases and size cannot be miniaturized
Solution Approach 1:
The integrated bobbin-core structure reduces the number of separate components that would require potting glue for assembly and protection. With fewer interfaces and a more compact monolithic structure, the overall volume of the magnetic component is reduced, enabling miniaturization while decreasing the amount of potting glue needed.
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 simplifies the assembly process, reduces the overall size and cost of the magnetic component, enhances its electrical characteristics, and stabilizes the appearance dimensions, while minimizing the use of potting glue and assembly time.
Implementation Method 1
The first core component comprises a first molding bobbin covering a first part of a core set by an injection molding process. The second core component comprises a second molding bobbin covering a second part of a core set by the injection molding process.
Data Source
AI summary
A magnetic component includes a first core component, a second core component and at least one coil. The first core component includes a first molding bobbin covering a first part of a core set by an injection molding process. The second core component includes a second molding bobbin covering a second part of the core set by the injection molding process. The first core component is assembled with the second core component to form a first pillar and a second pillar. Each of the first pillar and the second pillar includes a plurality of cores stacked with each other in a direction toward an outside or inside of the magnetic component. The at least one coil is wound on at least one of the first pillar and the second pillar.