Magnetic Element With Insertion Grooves for Assembly
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Solution Overview
Problem
Magnetic elements with closed magnetic paths, such as pot type, EER type, and EEP type cores, face challenges in assembly and resin filling due to the need for precise positioning of coil and outer peripheral core components, leading to increased working hours and a larger component count, as well as reduced flexibility in coil terminal arrangement.
Innovation Solution
A magnetic element design featuring a coil assembly with a core and outer peripheral core that includes an opening for insertion and a fixing unit, such as grooves or through holes, allowing for simplified assembly and reduced component count, using compression molded magnetic bodies for cores and injection molded magnetic bodies for outer peripheral cores, which can be separated and fixed without dividing, and incorporating spacers for improved workability and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise positioning is performed during assembly of coil and outer peripheral core, then assembly reliability is improved, but working hours and manufacturing complexity increase
Solution Approach 1:
The magnetic core is segmented into inner peripheral core and outer peripheral core as separate components. The inner peripheral core is inserted into the coil first, then the assembly is inserted into the outer peripheral core through a simplified positioning process using the opening structure, dividing the positioning task into two simpler steps rather than one complex simultaneous positioning operation
Solution Approach 2:
The opening in the outer peripheral core acts as an intermediary structure that facilitates the insertion and positioning of the coil assembly. This opening provides a guided path that automatically aligns the inner peripheral core and coil assembly with the outer peripheral core, reducing the need for complex external positioning mechanisms
2Reliability
If multiple components are combined to form hybrid magnetic element, then magnetic performance is improved, but component count and assembly complexity increase
Solution Approach 1:
The inner peripheral core and outer peripheral core are merged into a single integrated magnetic core structure that functions as one magnetic circuit. Although manufactured separately, they are designed to fit together precisely and are treated as a unified magnetic component, reducing the functional complexity despite physical separation for manufacturing reasons
3Strength
If coil terminal is arranged with large bending radius, then coil structural integrity is improved, but degree of freedom in terminal arrangement deteriorates
Solution Approach 1:
The coil terminals are arranged to extend in the axial direction of the magnetic core rather than only in the radial direction. This dimensional change provides additional freedom in terminal positioning while maintaining the required bending radius for structural integrity, as the axial direction offers more space and different routing options
Data Source
AI summary
To provide a magnetic element capable of reducing working man hour, the number of components, and an amount of a copper wire. A magnetic element 1 is provided with a coil assembly 4 including a core 2 formed by a compression molded magnetic body and a coil 3 wound on an outer periphery of the core 2, and an outer peripheral core 5 that surrounds an outer periphery of the coil assembly 4. The outer peripheral core 5 is formed by an injection molded magnetic body and includes an opening 5a into which the coil can be inserted, and a pair of grooves 5b into which both end portions in an axial direction of the core 2, the groove 5b being provided as a fixing unit for fixing the coil assembly 4 in the outer peripheral core and formed on an inner peripheral surface of the outer peripheral core.