Molded Power Inductor Assembly With Gapless Core Fit
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Solution Overview
Problem
Traditional power inductor manufacturing processes face issues such as virtual welding, open circuits, short circuits, deformation of conductors under high pressure, insufficient adhesive force between magnetic particles, and inefficient use of magnetic core volume due to gaps and high production costs, especially in miniaturization and thinning trends.
Innovation Solution
A molded-forming power inductor design featuring a conductor with an integrally formed insulation-processed base and side parts assembled gaplessly with a magnetic core, wrapped in a magnetic molding package layer, using a lower forming pressure and a method that includes prefabricating the conductor and magnetic core, and applying a molded-forming process with an organic layer cured by baking, ensuring a gapless fit and high bonding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure (900 MPa or above) is applied in compression molding forming process, then the coil and welding spot can be manufactured, but the welding spot, coil film and magnetic powder insulating layer are easily damaged causing open circuit and short circuit
Solution Approach 1:
The conductor is pre-assembled with the magnetic core in a gapless fit mode before the compression molding process. The coil is positioned and secured on the magnetic core with precise alignment features (groove bodies and positioning structures) prepared in advance, so that during compression molding the conductor and magnetic core are already in correct positional relationship, eliminating the need for high pressure to create the fit and reducing damage risk to welding spots and insulating layers
Solution Approach 2:
The patent changes the pressure parameter from traditional high pressure (900 MPa or above) to lower pressure (below 900 MPa) in the compression molding process. This parameter change is made possible by the pre-assembled gapless fit structure, which maintains manufacturing precision while reducing the harmful effects of high pressure on welding spots, coil film, and insulating layers
2Manufacturing precision
If high pressure is applied in compression molding, then the conductor can be formed, but the conductor is deformed
Solution Approach 1:
The conductor is pre-formed and pre-assembled with the magnetic core before compression molding. The base part, side enclosing parts, and electrode parts are already shaped and positioned correctly in advance, so the compression molding process only needs to secure the assembly rather than form the conductor shape, preventing deformation
Solution Approach 2:
The pressure parameter is reduced from traditional high pressure to below 900 MPa, which is sufficient to secure the pre-formed conductor assembly without causing deformation. The lower pressure maintains the conductor's shape while still achieving the necessary bonding and assembly fixation
3Ease of manufacture
If electrodes are led out from two sides of the magnet with side electrodes positioned outside the magnet, then the inductor can be manufactured, but the volume of the magnet cannot be fully utilized
Solution Approach 1:
The electrode parts are arranged in a planar configuration on the same plane as the magnetic core's lower surface, with electrodes extending from opposite sides. This two-dimensional layout optimizes space utilization by keeping electrodes coplanar with the core rather than extending beyond it in three-dimensional space, maximizing the magnetic core's volume utilization while maintaining manufacturability
4Ease of manufacture
If traditional combined magnetic core type power inductor with ferrite magnetic core and gap between conductor and magnetic core is used, then the inductor can be manufactured, but the leakage magnetic flux is large and it is easy to produce sound
Solution Approach 1:
The conductor's base part and side enclosing parts are assembled with the magnetic core in a gapless fit mode, merging the conductor and magnetic core into a tightly integrated assembly. The gapless fit eliminates air gaps between the conductor and magnetic core, preventing leakage magnetic flux and the associated sound generation, while still allowing for ease of manufacture through pre-formed components and positioning features
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
This design reduces leakage magnetic flux, enhances space utilization, maintains high inductance and current performance, and increases reliability by eliminating gaps and deformations, while allowing for miniaturization and high-frequency noise reduction.
Implementation Method 1
an organic layer of the magnetic molding package layer is cured by baking over 100° C. for 1 hour or more
Data Source
AI summary
A method is provided for manufacturing the molded-forming power inductor. The molding package layer completely covers the prefabricated magnetic core and a part of the conductor except the electrode, the structure is integrally formed, and the leakage magnetic flux is less; when the equivalent magnetic permeability is 60 or more, the equivalent saturation magnetic flux density can be 0.55T or higher; and the space utilization rate is high to facilitate miniaturization of an inductor design.