Magnetic Element With Insulating Base Protrusions For Automated Assembly
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Solution Overview
Problem
Conventional transformers assembled by automated machines face precision limitations, leading to enlarged dimensions due to increased pin distances, which affects the efficiency and compactness of magnetic elements.
Innovation Solution
A magnetic element design featuring a magnetic core set with a bobbin and insulating base, where the bobbin has conductive pins and guiding walls to securely hold the magnetic cores, and an insulating base with protrusions for stability, allowing automated assembly without enlarging dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated machines are used to assemble transformers, then productivity is improved, but manufacturing precision deteriorates due to limited assembly precision of automated machines
Solution Approach 1:
The magnetic element is divided into modular components (magnetic cores, bobbin, insulating base) with standardized interfaces. The guiding walls and positioning protrusions create segmented assembly zones that guide automated machines through discrete, precise placement steps, improving both productivity and precision.
Solution Approach 2:
The insulating base with positioning protrusions acts as an intermediary that mediates between the automated assembly machine and the magnetic cores. It provides physical guidance and positioning references that compensate for the limited precision of automated machines, enabling accurate assembly without sacrificing productivity.
2Ease of manufacture
If the distance between pins of the bobbin is increased to accommodate automated assembly, then ease of manufacture is improved, but the dimensions of the magnetic element are enlarged
Solution Approach 1:
Instead of increasing pin distance in the horizontal plane, the invention uses vertical dimension features (guiding walls extending upward, positioning protrusions on the insulating base) to provide assembly guidance. This allows compact horizontal dimensions while maintaining automated assembly capability through three-dimensional positioning features.
Solution Approach 2:
The guiding walls and positioning protrusions are pre-formed during manufacturing, creating built-in alignment features before assembly. This preliminary preparation eliminates the need for large pin distances during automated assembly, as the positioning features are already in place to guide component placement.
3Device complexity
If the magnetic core contacts the circuit board directly, then device complexity is reduced, but reliability deteriorates due to potential electrical interference and poor heat dissipation
Solution Approach 1:
The insulating base serves as an intermediary between the magnetic core and the circuit board. It provides electrical isolation to prevent interference while maintaining mechanical support and thermal pathways, thereby improving reliability without significantly increasing structural complexity.
Solution Approach 2:
The insulating base is made of insulating material that provides both electrical isolation and thermal management properties. This composite approach allows the magnetic core to be isolated electrically from the circuit board while still enabling heat dissipation through the insulating base material.
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
Enables precise and compact assembly of magnetic elements by automated machines, improving production yield and preventing direct contact between the magnetic core and circuit board, thus enhancing structural stability and heat dissipation.
Implementation Method 1
A transformer is a magnetic element capable of Electro-Magnetic Energy Conversion (EMEC) for adjusting voltage signal into a suitable range
Data Source
AI summary
A magnetic element is provided, including a magnetic core set, a bobbin, at least a wire, and an insulating base. The bobbin has a channel and a plurality of conductive pins, wherein the channel penetrates through the bobbin, and the magnetic core set is coupled with the channel. The wire is wound around the bobbin and connected to the conductive pins. The insulating base is connected to a bottom surface of the magnetic core set after the wire is wound around the bobbin and connected to the conductive pins, wherein the insulating base includes a plurality of protrusions adjacent to the conductive pins, respectively.