Molded Inductor Structure for Compact High-Current Shielding
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Solution Overview
Problem
Conventional inductive components face challenges in miniaturization, high current handling, and efficiency due to space constraints from shielding, air gaps, and the need for multiple manufacturing steps, which limits their applicability across various current and inductance applications.
Innovation Solution
The development of an electronic component with a tack core made of soft ferrite, wound with insulated wire, and over-molded or potted with a magnetic and/or non-magnetic material, featuring a unique design that allows for efficient compression molding or curing, reducing footprint and manufacturing complexity, and enabling customization for specific applications through varying ratios of powdered iron and ferrite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a cover is used to shield the coil winding, then electromagnetic interference is reduced and inductive component efficiency is improved, but the component occupies additional space and air gaps are created
Solution Approach 1:
The patent merges the shielding function with the structural body by making the body itself magnetic and enclosing the coil winding within it. This eliminates the need for a separate cover while maintaining shielding effectiveness and reducing overall component volume.
Solution Approach 2:
The magnetic body serves multiple functions simultaneously: it provides structural support, shields electromagnetic interference, and encloses the coil winding. This multi-functionality eliminates the need for separate shielding components and reduces air gaps.
2Productivity
If conventional inductive component structures are used, then manufacturing processes are established, but the components cannot be made smaller and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single compression molding process. The magnetic body and coil winding are formed together in one operation, eliminating subsequent assembly steps and reducing manufacturing complexity while enabling miniaturization.
Solution Approach 2:
The coil winding is positioned within the magnetic body material before the final curing process. This preliminary positioning allows the winding to be integrated into the body structure during molding, simplifying the overall manufacturing process and reducing the number of separate operations required.
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 approach enables the creation of compact, efficient inductive components that can handle high currents and achieve high inductance levels, while simplifying the manufacturing process and reducing costs, thus addressing the limitations of existing technologies.
Implementation Method 1
The mixture is then potted and cured to form a hardened inductor
Implementation Method 2
the shielding accomplished by the cover often takes up additional space and allows for unnecessary air gaps to exist in the component
Data Source
AI summary
An electronic component includes a wire winding wound around a central axis. The wire winding having first and second ends, and first and second terminals are connected to or formed by the first and second ends. The terminals provide electrical contacts for connecting the component into a circuit. The component has a wet press molded body made of a mixture of magnetic and non-magnetic material that is heated and pressed about the wire winding. The wet press molded body leaves at least a portion of the terminals exposed for mounting the component to the circuit.