Magnetic Element Vibration Resistance Fixing Structure

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Solution Overview

Problem

Magnetic elements mounted on electronic circuits in vibrating environments, such as automobiles, often experience connection failures due to destructive vibrations, leading to detachment and positional deviations of components.

Innovation Solution

A magnetic element design featuring a first magnetic core with a coil, a second magnetic core surrounding the first, and a metal terminal with a fixing portion that secures the second magnetic core, enhancing vibration-proof properties by using a combination of ferrite materials and strategically placed air gaps and solder fillets to prevent deformation and improve bonding strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the magnetic element is mounted on a mounting substrate in a vibrating environment, then the magnetic element can be used in applications such as automobiles, but the connecting portion between the mounting face and the metal terminal is easily destroyed by continuous vibration

Engineering Contradiction:

Improveapplicability in vibrating environmentsVSAvoidconnection strength

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The magnetic element is divided into separate components (first magnetic core, second magnetic core, metal terminal) that are combined together. The fixing portion is designed as a separate structural element that specifically addresses the connection issue between the magnetic core and mounting substrate, allowing this critical connection point to be optimized independently from other parts of the device.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fixing portion is designed in advance with a specific structure (protrusions fitting into recesses, or clamping structures) that prevents relative movement between components before vibration occurs. This preliminary structural arrangement ensures that when vibration is applied, the components are already secured in their proper positions and cannot easily detach.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If the metal terminal connects the coil and mounting substrate directly, then the structure is simple, but the connecting portion is easily destroyed by vibration causing detachment and positional deviation

Engineering Contradiction:

Improvestructural simplicityVSAvoidvibration resistance

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The fixing portion is designed with asymmetric features such as protrusions on one component that fit into corresponding recesses on another component, or clamping structures that apply force in specific directions. This asymmetric design creates a mechanically interlocked connection that resists vibration forces more effectively than symmetric or simple direct connections.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The fixing portion acts as an intermediary structure between the magnetic core and the mounting substrate. Rather than directly connecting the coil to the mounting substrate, the fixing portion mediates this connection by providing a specialized interface that enhances mechanical strength and vibration resistance while maintaining the functional connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the first magnetic core and second magnetic core are combined, then the magnetic element can fix the cores to improve vibration-proof properties, but the structure becomes more complex

Engineering Contradiction:

Improvevibration-proof propertiesVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The first magnetic core and second magnetic core are combined into a single functional unit with the metal terminal. The fixing portion is designed to simultaneously secure both cores together, creating a unified magnetic assembly. This merging approach improves vibration resistance by ensuring all magnetic components move together as one unit rather than independently.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The metal terminal serves multiple functions: it provides electrical connection for the coil, acts as a mounting interface for the magnetic cores, and includes the fixing portion that secures the cores together. This multi-functionality reduces the need for separate components for each function, thereby improving vibration resistance without proportionally increasing structural complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8471665B2Magnetic element

Publication Date: 2013.06.25 SUMIDA CORP

AI summary

A magnetic element including: a first magnetic core including a coil which is wound by a predetermined number of turns; a second magnetic core which includes the coil in the inside thereof and which is combined along the outer circumference of the first magnetic core; and a metal terminal which connects the coil and a mounting substrate, wherein the metal terminal includes a fixing portion for fixing the second magnetic core in a state of combining the first magnetic core and the second magnetic core.