Magnetic Element Recesses Enhance Insert Molding Fixing Strength
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Solution Overview
Problem
Conventional inductance elements with magnetic cores and resin bases fixed using insert molding face challenges in securing adequate fixing strength compared to adhesive methods.
Innovation Solution
The magnetic element incorporates a core with recesses or protrusions on its end surfaces to increase the contact area and resistance between the resin base and the core during insert molding, enhancing the fixing strength by increasing the contact area and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insert molding is used to fix the resin base to the core, then manufacturing steps are simplified, but fixing strength is insufficient compared to adhesive methods
Solution Approach 1:
The invention transitions from a simple surface contact fixation to a three-dimensional engagement by forming recesses in the core and corresponding protrusions in the base. This dimensional change allows the resin to be led into the recesses during insert molding, creating mechanical interlocking that significantly enhances fixing strength while maintaining the simplicity of the insert molding process.
Solution Approach 2:
The end surfaces of the core are segmented into multiple recesses rather than a single continuous surface. This segmentation increases the total contact area and creates multiple anchoring points for the resin base, thereby improving overall fixing strength while still using a single-step insert molding process.
2Strength
If adhesive is used to fix the base to the core, then fixing strength is sufficient, but manufacturing steps become more complex
Solution Approach 1:
The invention extracts the adhesive from the manufacturing process entirely by replacing it with mechanical interlocking features (recesses and protrusions). The resin base itself forms the fixing mechanism through insert molding, eliminating the need for separate adhesive application steps while maintaining or improving fixing strength.
Solution Approach 2:
The recesses in the core act as intermediaries that facilitate the bonding between the core and the resin base. During insert molding, the resin is led into these recesses, creating a mechanical bridge that transfers and distributes stress, thereby achieving strong fixation without requiring adhesive materials or additional processing steps.
Data Source
AI summary
Provided is a magnetic element capable of enhancing fixing strength of a base with respect to a core even if the base is fixed to the core by insert molding. A magnetic element (1) includes a core (2) made of a magnetic material, and resin bases (3 and 4) formed by insert molding so as to be fixed to end portions of the core (2), in which the core (2) is provided with a recess (2b) recessed from an end face (2a). In the magnetic element (1), it is possible to enhance the fixing strength of the bases (3 and 4) with respect to the core (2).