Monolithic Inductor Core with Integrated PCB Interfaces
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Solution Overview
Problem
Existing inductive coil components for printed circuit boards are prone to damage from drops and require a base or bobbin for mounting, which increases manufacturing costs and complexity.
Innovation Solution
A monolithic inductive coil component is created by fusing the magnetic core and base into a single, injection-moulded polymer body with integrated connecting interfaces, providing structural stability, electrical insulation, and shock absorbency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a base or bobbin is used to hold the magnetic core for mounting on PCB, then the component can be mounted on printed circuit boards, but the manufacturing cost increases and the structure becomes more complex
Solution Approach 1:
The patent combines the magnetic core and base into a single integrated component structure. The magnetic core is directly mounted on the PCB mounting surface without requiring a separate base or bobbin, merging two previously separate components into one unified structure that reduces both manufacturing complexity and cost.
Solution Approach 2:
The magnetic core is designed to perform multiple functions simultaneously: it provides the magnetic inductance function, serves as the mounting structure for the PCB, and eliminates the need for a separate base component. This multi-functionality approach reduces the overall component count and simplifies the structure.
2Reliability
If a base or bobbin is used to provide electrical insulation between the magnetic core and PCB, then electrical isolation is achieved, but the component requires additional parts and assembly steps
Solution Approach 1:
The mounting structure is integrated directly into the magnetic core assembly, combining the mechanical support function with the magnetic core itself. This eliminates the need for a separate base component while maintaining the electrical insulation properties through the integrated design.
Solution Approach 2:
The patent uses composite material structures within the magnetic core assembly that provide both mechanical support and electrical insulation properties simultaneously, eliminating the need for separate insulating base components.
3Reliability
If traditional inductive components are used, then they can be mounted on PCBs, but they are prone to damage from drops and shocks
Solution Approach 1:
The magnetic core and mounting structure are merged into a single robust assembly that can withstand mechanical shocks and drops. The integrated design eliminates weak points between separate components, improving overall structural reliability under mechanical stress.
Solution Approach 2:
The patent modifies the physical and mechanical parameters of the magnetic core assembly to enhance its durability. By changing the structural parameters and material properties of the integrated core-mounting structure, the component achieves improved resistance to mechanical shocks and drops while maintaining manufacturing simplicity.
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 monolithic design enhances drop resistance, simplifies manufacturing, and maintains the inductive component's properties such as inductance, Q factor, and sensitivity, while reducing costs and eliminating the need for additional cushioning.
Implementation Method 1
an injection mouldable polymer body including magnetic charges, comprised between 70% and up to a maximal proportion by weight of 85% selected to provide magnetic inductance
Implementation Method 2
assure electrical isolation between connecting interfaces that are integrated embedded in the monolithic core
Implementation Method 3
which is thermally conductive, with a thermal conductivity higher than 4W/mK
Data Source
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AI summary
A surface mounting inductive coiled component for printed circuit boards is proposed. The component comprises at least one winding groove for the arrangement of at least one conductive coil to be wounded around a monolithic core (1), and several connecting interfaces (2) attached to the monolithic core (1) for connecting the at least one conductive coil to the tracks of a circuit board, wherein the monolithic core is made of an injection mouldable polymer body including magnetic charges in a proportion comprised between 70% up to 85% by weight, selected to provide magnetic inductance and assure electrical isolation between the connecting interfaces that are integrated in the monolithic core which is thermally conductive and wherein the magnetic charges include powdered magnetic charges or the magnetic charges include powdered magnetic charges and further include at least one solid sintered core (3) of magnetic material embedded in the polymer body.