Magnetic Module Base Terminal Fixing
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Solution Overview
Problem
Conventional magnetic modules, such as inductors, face issues with terminal deformation and poor contact during reflow furnaces, leading to performance deterioration due to difficulty in fixing conductive assemblies on circuit boards and potential short-circuiting.
Innovation Solution
A magnetic module with a base that includes conductive structures to securely engage and fix the terminals of a conductive assembly, minimizing deformation and ensuring even contact by using position-limiting structures and protrusion parts to maintain alignment and stability during assembly and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the conductive assembly is produced by a wider conductive sheet to handle larger voltage, then the voltage handling capability is improved, but the conductive assembly becomes difficult to fix on the circuit board and may become aslant causing short-circuiting
Solution Approach 1:
The conductive assembly is divided into multiple conductive portions, each corresponding to different terminals. This segmentation allows each portion to be independently supported by the base, preventing deformation and ensuring reliable fixing even when the overall assembly is wide enough to handle larger voltages.
Solution Approach 2:
The base acts as an intermediary component between the conductive assembly and the circuit board. The base provides mechanical support and positioning for the conductive assembly, preventing it from becoming aslant or deforming during assembly and reflow processes, thus ensuring reliable fixing.
2Extent of automation
If the terminals are attached to the circuit board by surface mount technology using a placement machine, then the assembly process is automated, but the high temperature during reflow furnace transfer may deform the terminals
Solution Approach 1:
The base provides preliminary support and positioning for the terminals before they undergo the reflow furnace process. The conductive structures on the base hold the terminals in a predetermined position, preventing deformation during high-temperature processing and ensuring manufacturing precision is maintained throughout automation.
3Shape
If the bottom surfaces of the terminals have reduced evenness, then the inductor fails to lie flat on the circuit board, but fixing the conductive assembly securely requires additional structural complexity
Solution Approach 1:
The base serves as an intermediary that compensates for terminal evenness issues. The conductive structures on the base provide stable contact surfaces with the circuit board, allowing the magnetic module to lie flat even when terminal bottom surfaces have reduced evenness, without requiring complex additional structural elements.
Data Source
AI summary
A magnetic module includes a magnetic element and a base. The magnetic element includes a conductive assembly and a magnetic core assembly. The conductive assembly includes a plurality of terminals. The magnetic core assembly is partially embedded within the conductive assembly. The base includes a base body and a plurality of conductive structures. The base body has a first surface, wherein the magnetic element is disposed on the first surface. The conductive structures are disposed on the base body and engaged with the plurality of terminals, so that the plurality of terminals are fixed by and electrically connected with the plurality of conductive structures, respectively.