Molding Inductor Magnetic Force Compression
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Solution Overview
Problem
Conventional molding inductor manufacturing methods face issues with nonuniform density distribution and damage to enameled wires due to friction forces and excessive molding stress.
Innovation Solution
A method and apparatus using a magnetic force generating unit to apply a magnetic force to molding material doped with ferrite powder, eliminating friction forces and reducing the risk of damage to enameled wires by using a mold with accommodating grooves for coils, allowing the material to be molded under controlled magnetic stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punching members are used to apply molding stress to the molding material, then the molding material can be compressed into a molded body, but friction force is generated between the molding material and the inner walls of the accommodating groove causing nonuniform density distribution
Solution Approach 1:
The patent replaces the conventional mechanical punching system with a magnetic field-based molding system. Electromagnets are positioned around the accommodating groove to apply magnetic force to the magnetic ferrite powder within the molding material, enabling compression without mechanical contact between the molding material and the groove walls, thereby eliminating friction-induced density nonuniformity
Solution Approach 2:
The patent changes the state of the molding material by incorporating magnetic ferrite powder, which enables the material to respond to magnetic fields. This parameter change allows the material to be manipulated by magnetic force rather than mechanical force, fundamentally altering the molding mechanism to eliminate friction
2Manufacturing precision
If excessive molding stress is applied to achieve proper molding, then the molding material can be sufficiently compressed, but the enameled wire of the coil is damaged
Solution Approach 1:
The patent substitutes mechanical compression with magnetic field compression. The electromagnetic force can be precisely controlled and distributed uniformly throughout the molding material, achieving sufficient compression density without the localized excessive stress that damages the enameled wire in conventional mechanical molding
Solution Approach 2:
The magnetic field acts as an intermediary between the molding system and the molding material. Instead of direct mechanical contact that concentrates stress, the magnetic field uniformly distributes compressive force throughout the material volume, protecting the embedded coil while achieving proper molding density
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
The method achieves uniform density distribution in molded bodies and prevents damage to enameled wires by eliminating friction forces and optimizing the molding stress, resulting in higher quality molding inductors.
Implementation Method 1
the magnetic force generating unit is configured to apply a magnetic force to the accommodating groove, thereby making the molding material become to a molded body in the accommodation space under a molding stress provided by the magnetic force
Data Source
AI summary
The present invention discloses an apparatus and a method for manufacturing molding inductor. The apparatus mainly comprises a mold and at least one magnetic force generating unit. Particularly, the mold is designed to have one or more accommodation spaces to correspondingly receive one or more coils. On the other hand, the magnetic force generating unit is configured to apply a magnetic force to the accommodation spaces after a molding material doped with magnetic ferrite powder is filled into the accommodation spaces receiving with the coil therein. Consequently, the molding material is forced by a molding stress provided by the applied magnetic force to move effectively downward in the accommodation space, such that a molded body is eventually formed in the accommodation space.